Chevrolet - Tahoe 4wd - Workshop Manual - 2007 - 2007

Factory Workshop Manual Make Chevrolet Model Tahoe 4wd Engine and year V8-5.3L (2007) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Steering Column Components Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 7 Theft Deterrent Control Module Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8 Alarm Module: Service and Repair THEFT DETERRENT MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations Behind The I/P Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Page 12 Central Control Module: Diagrams Vehicle Communication Interface Module (VCIM) C1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Page 13 Vehicle Communication Interface Module (VCIM) C2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Page 14 Vehicle Communication Interface Module (VCIM) C3 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Page 15 Central Control Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT (EXCEPT CADILLAC) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 24 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 25 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 26 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 32 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 33 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 34 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 39 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 45 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 54 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 59 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 64 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 65 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 71 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 80 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-002 > Jun > 08 > OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 97 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 102 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 103 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 108 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 109 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 110 Method 1 Method 2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 111 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 121 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-002 > Jun > 08 > OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 138 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 139 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 140 Method 1 Method 2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 141 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams Infrared Module (With RPO Code U42) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Page 145 Entertainment System Control Module: Service and Repair AUDIO SYSTEM TRANSCEIVER MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming Technical Service Bulletin # 07007C Date: 070215 Campaign - Keyless Entry Transmitter/Module Programming Subject: Service Update for Inventory and Customer Vehicles-Remote Keyless Entry (RKE) Inoperative and Battery Rundown - Expires with Base Warranty # 07007C - (02/15/2007) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon XL 2007 Pontiac Torrent THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07007AB ISSUED FEBRUARY 2007. TECHNICIAN MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICIANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON TO ASSIST IN IMPROVING PERFORMANCE AND REDUCE PROGRAMMING TIME IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED USING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. This bulletin provides a service procedure for reprogramming the remote control door lock receiver (RCDLR) and the remote keyless entry transmitter (FOB) on certain 2006-2007 Buick Lucerne; 2006-2007 Cadillac DTS; 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX; 2006-2007 Chevrolet Impala, Monte Carlo; 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe; 2007 GMC Yukon, Yukon XL; and 2007 Pontiac Torrent vehicles. On these vehicles, the RKE may become inoperative. Also, for the 2007 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL vehicles (GMT900 Utility) only, this bulletin provides a service procedure for reprogramming the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 154 Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Claim Information Programming Remote Keyless Entry Transmitters Using the Driver Information Center (DIC) All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at the same time, including the one programmed at the dealership. Those transmitters not programmed at the same time will not function properly. Follow the procedure below for programming. This procedure is also published in the Owner Manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 155 RELEARN REMOTE KEY The Driver Information Center (DIC) display allows you to match the remote keyless entry transmitter to your vehicle. To match a remote keyless entry transmitter to your vehicle do the following: 1. Press the vehicle information button until RELEARN REMOTE KEY displays. 2. Press the set/reset button. 3. Press and hold the lock and unlock buttons on the first transmitter at the same time for approximately 15 seconds. On vehicles with memory recall seats, the first transmitter learned will match driver 1 and the second will match driver 2. 4. To match additional transmitters at this time, repeat step 3 with each new transmitter. Each vehicle can have a maximum of eight transmitters matched to it. 5. To exit the programming mode, you must cycle the key to the OFF/LOCK position. Disclaimer Service Procedure Important: Technicians may experience low performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicans may notice the lower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if low performance is experienced. Important: This bulletin contains two reprogramming procedures, 1) reprogramming of the BCM, and 2) reprogramming of the RCDLR. Not all vehicles require reprogramming of both. ^ The Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon and Yukon XL vehicles require the BCM and RCDLR reprogramming. ^ The Buick Lucerne; Cadillac DTS; Chevrolet Impala, Monte Carlo; Chevrolet Equinox; and Pontiac Torrent require only the RCDLR reprogramming - DO NOT ATTEMPT TO REPROGRAM THE BCM ON THESE VEHICLES. Body Control Module Reprogramming - For Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL ONLY: Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 156 Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery. Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controlers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech2(R). 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2(R). 14. Go into diagnostics and check for DTC codes. 15. Clear all codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 157 Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the IPC 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. 16. Proceed to RCDLR Reprogramming. RCDLR Reprogramming - For All Vehicles Important: The Tech 2 diagnostic tool must be updated with version 27.003 or later for reprogramming the Remote Control Door Lock Receiver (RCDLR). The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 10 for 2006 (available on 10/01/06) and on TIS DVD version 10/2006 or later that was mailed to dealers on October 18, 2006. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for Remote Control Door Lock Receiver (RCDLR) Important: The Copy and Paste procedure in Step 7 does not apply to 2006 Lucerne vehicles. Please refer to the appropriate Tire Pressure Monitor reset procedure in SI. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. 2. Turn on the Tech2(R). 3. Build the vehicle using the Tech 2(R). 4. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 5. Write down all four Pressure Sensor IDs on a sheet of paper. 6. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. Important: If "Replace Module Per Service Manual" message appears on the Tech 2 during this procedure, ignore the message and press the "Exit" key on the Tech 2 and proceed to the next step. Do NOT replace the module. 7. Run the Copy and Paste TPM Information Procedure (FO: Step 1). Follow the on-screen instructions: Turn the ignition to the ON position with the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 158 engine OFF. 8. Turn off the Tech 2. 9. Turn on the Tech2. 10. Connect the Tech 2 to the vehicle and the TIS terminal. 11. On the TIS terminal go into SPS Programming. 12. Select Pass Thru programming. 13. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen: 13.1. Scroll down in the top box and select RCDLR (Remote Control Door Lock Receiver). 13.2. In the lower box select Normal. 13.3. Select Next. Important: Some vehicles will require additional selections in the module field before you can proceed and the "Next" button is functional. 14. When the Calibration Screen displays, select calibration 25808841 for vehicles that are NOT equipped with the remote start feature or calibration 25808842 for vehicles that are equipped with the remote start feature. After selecting a calibration, select Next. 15. Follow the on-screen prompts until programming is completed. 16. When programming is complete: 16.1. Turn off Tech2. 16.2. Turn the ignition switch to the OFF position. 17. Wait 30 seconds~. 18. Turn the ignition switch to the ON position with engine OFF. 19. Turn on the Tech 2. 20. Build the vehicle using the Tech 2. 21. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. 22. Run the Copy and Paste TPM Information Procedure (F1: Step 2). 23. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 24. Verify that the four Pressure Sensor IDs match those that were recorded in Step 5. 25. Go into diagnostics and check for DTC codes. 26. Clear all codes. Programming Remote Keyless Entry Transmitters (Vehicles in Inventory) Important: All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made or the RCDLR module has been reprogrammed, all learned transmitters are erased. Up to 8 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. Program remote keyless entry transmitters. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 159 2. Select Next Available Slot. Follow the on-screen instructions. Simultaneously hold the LOCK and UNLOCK buttons on the keyless entry transmitter to program. 3. When all the desired transmitters have been programmed, exit the vehicle and operate the transmitter functions in order to verify correct system operation. Programming Remote Keyless Entry Transmitters (Sold Vehicles) Important: Make several copies of the programming instructions if required. Some customers may not bring all of their remote keyless entry transmitters to your dealership for programming. Vehicles are sold with two transmitters. However, customers have the option to purchase additional transmitters. Ensure that customers understand that all of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at one time in order to function properly. Program the transmitters that the customer provides to you using a scan tool. Inform the customer that all of the remaining transmitters will not function properly until they are programmed. Customers must program all of their transmitters, including the transmitters programmed at your dealership, at one time, using the driver information center (DIC) programming method. Inform customers to locate and program their transmitters using the procedure provided. This procedure is also published in the owner manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed Keyless Entry Module: Customer Interest Keyless Systems - Poor Range/TPM Message Displayed TECHNICAL Bulletin No.: 06-08-52-002G Date: November 24, 2008 Subject: Remote Keyless Entry (RKE) Inoperative, Poor Range, Tire Pressure Monitor (TPM) Message Displayed, Remote Vehicle Start (RVS) (Replace RKE Transmitters and Reprogram Remote Control Door Lock Receiver (RCDLR)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007 Pontiac Torrent Supercede: This bulletin is being revised to update the Part Information. Please discard Corporate Bulletin Number 06-08-52-002F (Section 08 - Body & Accessories). Condition Some customers may comment about one or more of the following conditions: ^ The remote keyless entry (RKE) transmitters will not program, function and/or the RKE transmitter low battery message is displayed. ^ The Service Tire Monitor System message is displayed. ^ The new RKE transmitters cannot be programmed. ^ The remote keyless entry (RKE) and/or remote vehicle start (RVS) transmitter has poor range. Cause Any of these concerns may be caused by an internal fault with the transmitters and/or the RCDLR software/hardware. Correction Important: Check VIS to determine if Inventory Upgrade 07007 applies and has been completed. If the vehicle is listed in the Inventory Upgrade, and the upgrade has not been performed, complete the Inventory Upgrade before proceeding with this bulletin. DO NOT REPLACE THE BCM OR RADIO ANTENNA MODULE. Complete the following repair procedures: Important: When programming a new or existing RCDLR, the programming instructions in SI must be followed. ^ On vehicles equipped with Tire Pressure Monitoring (TPM), the tire type and tire pressures must be selected in the module set-up using the Tech 2(R). If this step is not performed, the RCDLR will not retain the tire pressures after the TPM system is learned. Tip: When selecting the Tire Type/Pressure, choose the appropriate selection on the Tech 2 based on psi, not kPa. ^ Relearn the TPM sensors using the J 46079 and following the procedure found in SI. ^ After the learn procedure is complete, be sure to set the tire pressures according to the information on the tire placard. Important: If the Inventory upgrade 07007 has been performed, skip the initial RCDLR programming step #1 and proceed to step # 2. Reprogram the RCDLR with the latest software update available through TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 165 Important: New transmitters are identified by a star on the back of the transmitter. It is important to verify that the replacement transmitters have a star on the back. 1. Replace both Remote Keyless Entry transmitters. 2. Program the transmitters using the procedure listed in SI. 3. Perform the following steps in the exact order: 1. Remove the key from the ignition. 2. Open and close the driver's door. 3. Close all other doors/trunk/liftgates. 4. Wait 5 minutes. 5. Press the Unlock Button and verify that the doors all unlock. ^ If the customer's concerns are corrected, no further repairs are required. ^ If the customer's concerns are NOT corrected, proceed with step 5. Important: In most cases, steps 1-3 will correct the customer's concern. In a few cases, it may be necessary to replace the RCDLR. 4. If the customer's concern is still present, replace the RCDLR. 5. Program the RCDLR with the latest software update available through TIS2WEB. 6. Reprogram both Remote Keyless Entry Transmitters. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 166 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed Keyless Entry Module: All Technical Service Bulletins Keyless Systems - Poor Range/TPM Message Displayed TECHNICAL Bulletin No.: 06-08-52-002G Date: November 24, 2008 Subject: Remote Keyless Entry (RKE) Inoperative, Poor Range, Tire Pressure Monitor (TPM) Message Displayed, Remote Vehicle Start (RVS) (Replace RKE Transmitters and Reprogram Remote Control Door Lock Receiver (RCDLR)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007 Pontiac Torrent Supercede: This bulletin is being revised to update the Part Information. Please discard Corporate Bulletin Number 06-08-52-002F (Section 08 - Body & Accessories). Condition Some customers may comment about one or more of the following conditions: ^ The remote keyless entry (RKE) transmitters will not program, function and/or the RKE transmitter low battery message is displayed. ^ The Service Tire Monitor System message is displayed. ^ The new RKE transmitters cannot be programmed. ^ The remote keyless entry (RKE) and/or remote vehicle start (RVS) transmitter has poor range. Cause Any of these concerns may be caused by an internal fault with the transmitters and/or the RCDLR software/hardware. Correction Important: Check VIS to determine if Inventory Upgrade 07007 applies and has been completed. If the vehicle is listed in the Inventory Upgrade, and the upgrade has not been performed, complete the Inventory Upgrade before proceeding with this bulletin. DO NOT REPLACE THE BCM OR RADIO ANTENNA MODULE. Complete the following repair procedures: Important: When programming a new or existing RCDLR, the programming instructions in SI must be followed. ^ On vehicles equipped with Tire Pressure Monitoring (TPM), the tire type and tire pressures must be selected in the module set-up using the Tech 2(R). If this step is not performed, the RCDLR will not retain the tire pressures after the TPM system is learned. Tip: When selecting the Tire Type/Pressure, choose the appropriate selection on the Tech 2 based on psi, not kPa. ^ Relearn the TPM sensors using the J 46079 and following the procedure found in SI. ^ After the learn procedure is complete, be sure to set the tire pressures according to the information on the tire placard. Important: If the Inventory upgrade 07007 has been performed, skip the initial RCDLR programming step #1 and proceed to step # 2. Reprogram the RCDLR with the latest software update available through TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 172 Important: New transmitters are identified by a star on the back of the transmitter. It is important to verify that the replacement transmitters have a star on the back. 1. Replace both Remote Keyless Entry transmitters. 2. Program the transmitters using the procedure listed in SI. 3. Perform the following steps in the exact order: 1. Remove the key from the ignition. 2. Open and close the driver's door. 3. Close all other doors/trunk/liftgates. 4. Wait 5 minutes. 5. Press the Unlock Button and verify that the doors all unlock. ^ If the customer's concerns are corrected, no further repairs are required. ^ If the customer's concerns are NOT corrected, proceed with step 5. Important: In most cases, steps 1-3 will correct the customer's concern. In a few cases, it may be necessary to replace the RCDLR. 4. If the customer's concern is still present, replace the RCDLR. 5. Program the RCDLR with the latest software update available through TIS2WEB. 6. Reprogram both Remote Keyless Entry Transmitters. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 173 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming Technical Service Bulletin # 07007C Date: 070215 Campaign - Keyless Entry Transmitter/Module Programming Subject: Service Update for Inventory and Customer Vehicles-Remote Keyless Entry (RKE) Inoperative and Battery Rundown - Expires with Base Warranty # 07007C - (02/15/2007) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon XL 2007 Pontiac Torrent THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07007AB ISSUED FEBRUARY 2007. TECHNICIAN MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICIANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON TO ASSIST IN IMPROVING PERFORMANCE AND REDUCE PROGRAMMING TIME IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED USING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. This bulletin provides a service procedure for reprogramming the remote control door lock receiver (RCDLR) and the remote keyless entry transmitter (FOB) on certain 2006-2007 Buick Lucerne; 2006-2007 Cadillac DTS; 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX; 2006-2007 Chevrolet Impala, Monte Carlo; 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe; 2007 GMC Yukon, Yukon XL; and 2007 Pontiac Torrent vehicles. On these vehicles, the RKE may become inoperative. Also, for the 2007 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL vehicles (GMT900 Utility) only, this bulletin provides a service procedure for reprogramming the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 178 Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Claim Information Programming Remote Keyless Entry Transmitters Using the Driver Information Center (DIC) All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at the same time, including the one programmed at the dealership. Those transmitters not programmed at the same time will not function properly. Follow the procedure below for programming. This procedure is also published in the Owner Manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 179 RELEARN REMOTE KEY The Driver Information Center (DIC) display allows you to match the remote keyless entry transmitter to your vehicle. To match a remote keyless entry transmitter to your vehicle do the following: 1. Press the vehicle information button until RELEARN REMOTE KEY displays. 2. Press the set/reset button. 3. Press and hold the lock and unlock buttons on the first transmitter at the same time for approximately 15 seconds. On vehicles with memory recall seats, the first transmitter learned will match driver 1 and the second will match driver 2. 4. To match additional transmitters at this time, repeat step 3 with each new transmitter. Each vehicle can have a maximum of eight transmitters matched to it. 5. To exit the programming mode, you must cycle the key to the OFF/LOCK position. Disclaimer Service Procedure Important: Technicians may experience low performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicans may notice the lower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if low performance is experienced. Important: This bulletin contains two reprogramming procedures, 1) reprogramming of the BCM, and 2) reprogramming of the RCDLR. Not all vehicles require reprogramming of both. ^ The Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon and Yukon XL vehicles require the BCM and RCDLR reprogramming. ^ The Buick Lucerne; Cadillac DTS; Chevrolet Impala, Monte Carlo; Chevrolet Equinox; and Pontiac Torrent require only the RCDLR reprogramming - DO NOT ATTEMPT TO REPROGRAM THE BCM ON THESE VEHICLES. Body Control Module Reprogramming - For Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL ONLY: Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 180 Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery. Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controlers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech2(R). 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2(R). 14. Go into diagnostics and check for DTC codes. 15. Clear all codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 181 Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the IPC 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. 16. Proceed to RCDLR Reprogramming. RCDLR Reprogramming - For All Vehicles Important: The Tech 2 diagnostic tool must be updated with version 27.003 or later for reprogramming the Remote Control Door Lock Receiver (RCDLR). The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 10 for 2006 (available on 10/01/06) and on TIS DVD version 10/2006 or later that was mailed to dealers on October 18, 2006. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for Remote Control Door Lock Receiver (RCDLR) Important: The Copy and Paste procedure in Step 7 does not apply to 2006 Lucerne vehicles. Please refer to the appropriate Tire Pressure Monitor reset procedure in SI. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. 2. Turn on the Tech2(R). 3. Build the vehicle using the Tech 2(R). 4. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 5. Write down all four Pressure Sensor IDs on a sheet of paper. 6. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. Important: If "Replace Module Per Service Manual" message appears on the Tech 2 during this procedure, ignore the message and press the "Exit" key on the Tech 2 and proceed to the next step. Do NOT replace the module. 7. Run the Copy and Paste TPM Information Procedure (FO: Step 1). Follow the on-screen instructions: Turn the ignition to the ON position with the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 182 engine OFF. 8. Turn off the Tech 2. 9. Turn on the Tech2. 10. Connect the Tech 2 to the vehicle and the TIS terminal. 11. On the TIS terminal go into SPS Programming. 12. Select Pass Thru programming. 13. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen: 13.1. Scroll down in the top box and select RCDLR (Remote Control Door Lock Receiver). 13.2. In the lower box select Normal. 13.3. Select Next. Important: Some vehicles will require additional selections in the module field before you can proceed and the "Next" button is functional. 14. When the Calibration Screen displays, select calibration 25808841 for vehicles that are NOT equipped with the remote start feature or calibration 25808842 for vehicles that are equipped with the remote start feature. After selecting a calibration, select Next. 15. Follow the on-screen prompts until programming is completed. 16. When programming is complete: 16.1. Turn off Tech2. 16.2. Turn the ignition switch to the OFF position. 17. Wait 30 seconds~. 18. Turn the ignition switch to the ON position with engine OFF. 19. Turn on the Tech 2. 20. Build the vehicle using the Tech 2. 21. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. 22. Run the Copy and Paste TPM Information Procedure (F1: Step 2). 23. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 24. Verify that the four Pressure Sensor IDs match those that were recorded in Step 5. 25. Go into diagnostics and check for DTC codes. 26. Clear all codes. Programming Remote Keyless Entry Transmitters (Vehicles in Inventory) Important: All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made or the RCDLR module has been reprogrammed, all learned transmitters are erased. Up to 8 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. Program remote keyless entry transmitters. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 183 2. Select Next Available Slot. Follow the on-screen instructions. Simultaneously hold the LOCK and UNLOCK buttons on the keyless entry transmitter to program. 3. When all the desired transmitters have been programmed, exit the vehicle and operate the transmitter functions in order to verify correct system operation. Programming Remote Keyless Entry Transmitters (Sold Vehicles) Important: Make several copies of the programming instructions if required. Some customers may not bring all of their remote keyless entry transmitters to your dealership for programming. Vehicles are sold with two transmitters. However, customers have the option to purchase additional transmitters. Ensure that customers understand that all of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at one time in order to function properly. Program the transmitters that the customer provides to you using a scan tool. Inform the customer that all of the remaining transmitters will not function properly until they are programmed. Customers must program all of their transmitters, including the transmitters programmed at your dealership, at one time, using the driver information center (DIC) programming method. Inform customers to locate and program their transmitters using the procedure provided. This procedure is also published in the owner manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed Keyless Entry Module: All Technical Service Bulletins Keyless Systems - Poor Range/TPM Message Displayed TECHNICAL Bulletin No.: 06-08-52-002G Date: November 24, 2008 Subject: Remote Keyless Entry (RKE) Inoperative, Poor Range, Tire Pressure Monitor (TPM) Message Displayed, Remote Vehicle Start (RVS) (Replace RKE Transmitters and Reprogram Remote Control Door Lock Receiver (RCDLR)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007 Pontiac Torrent Supercede: This bulletin is being revised to update the Part Information. Please discard Corporate Bulletin Number 06-08-52-002F (Section 08 - Body & Accessories). Condition Some customers may comment about one or more of the following conditions: ^ The remote keyless entry (RKE) transmitters will not program, function and/or the RKE transmitter low battery message is displayed. ^ The Service Tire Monitor System message is displayed. ^ The new RKE transmitters cannot be programmed. ^ The remote keyless entry (RKE) and/or remote vehicle start (RVS) transmitter has poor range. Cause Any of these concerns may be caused by an internal fault with the transmitters and/or the RCDLR software/hardware. Correction Important: Check VIS to determine if Inventory Upgrade 07007 applies and has been completed. If the vehicle is listed in the Inventory Upgrade, and the upgrade has not been performed, complete the Inventory Upgrade before proceeding with this bulletin. DO NOT REPLACE THE BCM OR RADIO ANTENNA MODULE. Complete the following repair procedures: Important: When programming a new or existing RCDLR, the programming instructions in SI must be followed. ^ On vehicles equipped with Tire Pressure Monitoring (TPM), the tire type and tire pressures must be selected in the module set-up using the Tech 2(R). If this step is not performed, the RCDLR will not retain the tire pressures after the TPM system is learned. Tip: When selecting the Tire Type/Pressure, choose the appropriate selection on the Tech 2 based on psi, not kPa. ^ Relearn the TPM sensors using the J 46079 and following the procedure found in SI. ^ After the learn procedure is complete, be sure to set the tire pressures according to the information on the tire placard. Important: If the Inventory upgrade 07007 has been performed, skip the initial RCDLR programming step #1 and proceed to step # 2. Reprogram the RCDLR with the latest software update available through TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 189 Important: New transmitters are identified by a star on the back of the transmitter. It is important to verify that the replacement transmitters have a star on the back. 1. Replace both Remote Keyless Entry transmitters. 2. Program the transmitters using the procedure listed in SI. 3. Perform the following steps in the exact order: 1. Remove the key from the ignition. 2. Open and close the driver's door. 3. Close all other doors/trunk/liftgates. 4. Wait 5 minutes. 5. Press the Unlock Button and verify that the doors all unlock. ^ If the customer's concerns are corrected, no further repairs are required. ^ If the customer's concerns are NOT corrected, proceed with step 5. Important: In most cases, steps 1-3 will correct the customer's concern. In a few cases, it may be necessary to replace the RCDLR. 4. If the customer's concern is still present, replace the RCDLR. 5. Program the RCDLR with the latest software update available through TIS2WEB. 6. Reprogram both Remote Keyless Entry Transmitters. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 190 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming Technical Service Bulletin # 07007C Date: 070215 Campaign - Keyless Entry Transmitter/Module Programming Subject: Service Update for Inventory and Customer Vehicles-Remote Keyless Entry (RKE) Inoperative and Battery Rundown - Expires with Base Warranty # 07007C - (02/15/2007) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon XL 2007 Pontiac Torrent THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07007AB ISSUED FEBRUARY 2007. TECHNICIAN MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICIANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON TO ASSIST IN IMPROVING PERFORMANCE AND REDUCE PROGRAMMING TIME IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED USING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. This bulletin provides a service procedure for reprogramming the remote control door lock receiver (RCDLR) and the remote keyless entry transmitter (FOB) on certain 2006-2007 Buick Lucerne; 2006-2007 Cadillac DTS; 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX; 2006-2007 Chevrolet Impala, Monte Carlo; 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe; 2007 GMC Yukon, Yukon XL; and 2007 Pontiac Torrent vehicles. On these vehicles, the RKE may become inoperative. Also, for the 2007 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL vehicles (GMT900 Utility) only, this bulletin provides a service procedure for reprogramming the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 196 Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Claim Information Programming Remote Keyless Entry Transmitters Using the Driver Information Center (DIC) All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at the same time, including the one programmed at the dealership. Those transmitters not programmed at the same time will not function properly. Follow the procedure below for programming. This procedure is also published in the Owner Manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 197 RELEARN REMOTE KEY The Driver Information Center (DIC) display allows you to match the remote keyless entry transmitter to your vehicle. To match a remote keyless entry transmitter to your vehicle do the following: 1. Press the vehicle information button until RELEARN REMOTE KEY displays. 2. Press the set/reset button. 3. Press and hold the lock and unlock buttons on the first transmitter at the same time for approximately 15 seconds. On vehicles with memory recall seats, the first transmitter learned will match driver 1 and the second will match driver 2. 4. To match additional transmitters at this time, repeat step 3 with each new transmitter. Each vehicle can have a maximum of eight transmitters matched to it. 5. To exit the programming mode, you must cycle the key to the OFF/LOCK position. Disclaimer Service Procedure Important: Technicians may experience low performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicans may notice the lower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if low performance is experienced. Important: This bulletin contains two reprogramming procedures, 1) reprogramming of the BCM, and 2) reprogramming of the RCDLR. Not all vehicles require reprogramming of both. ^ The Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon and Yukon XL vehicles require the BCM and RCDLR reprogramming. ^ The Buick Lucerne; Cadillac DTS; Chevrolet Impala, Monte Carlo; Chevrolet Equinox; and Pontiac Torrent require only the RCDLR reprogramming - DO NOT ATTEMPT TO REPROGRAM THE BCM ON THESE VEHICLES. Body Control Module Reprogramming - For Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL ONLY: Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 198 Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery. Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controlers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech2(R). 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2(R). 14. Go into diagnostics and check for DTC codes. 15. Clear all codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 199 Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the IPC 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. 16. Proceed to RCDLR Reprogramming. RCDLR Reprogramming - For All Vehicles Important: The Tech 2 diagnostic tool must be updated with version 27.003 or later for reprogramming the Remote Control Door Lock Receiver (RCDLR). The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 10 for 2006 (available on 10/01/06) and on TIS DVD version 10/2006 or later that was mailed to dealers on October 18, 2006. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for Remote Control Door Lock Receiver (RCDLR) Important: The Copy and Paste procedure in Step 7 does not apply to 2006 Lucerne vehicles. Please refer to the appropriate Tire Pressure Monitor reset procedure in SI. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. 2. Turn on the Tech2(R). 3. Build the vehicle using the Tech 2(R). 4. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 5. Write down all four Pressure Sensor IDs on a sheet of paper. 6. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. Important: If "Replace Module Per Service Manual" message appears on the Tech 2 during this procedure, ignore the message and press the "Exit" key on the Tech 2 and proceed to the next step. Do NOT replace the module. 7. Run the Copy and Paste TPM Information Procedure (FO: Step 1). Follow the on-screen instructions: Turn the ignition to the ON position with the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 200 engine OFF. 8. Turn off the Tech 2. 9. Turn on the Tech2. 10. Connect the Tech 2 to the vehicle and the TIS terminal. 11. On the TIS terminal go into SPS Programming. 12. Select Pass Thru programming. 13. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen: 13.1. Scroll down in the top box and select RCDLR (Remote Control Door Lock Receiver). 13.2. In the lower box select Normal. 13.3. Select Next. Important: Some vehicles will require additional selections in the module field before you can proceed and the "Next" button is functional. 14. When the Calibration Screen displays, select calibration 25808841 for vehicles that are NOT equipped with the remote start feature or calibration 25808842 for vehicles that are equipped with the remote start feature. After selecting a calibration, select Next. 15. Follow the on-screen prompts until programming is completed. 16. When programming is complete: 16.1. Turn off Tech2. 16.2. Turn the ignition switch to the OFF position. 17. Wait 30 seconds~. 18. Turn the ignition switch to the ON position with engine OFF. 19. Turn on the Tech 2. 20. Build the vehicle using the Tech 2. 21. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. 22. Run the Copy and Paste TPM Information Procedure (F1: Step 2). 23. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 24. Verify that the four Pressure Sensor IDs match those that were recorded in Step 5. 25. Go into diagnostics and check for DTC codes. 26. Clear all codes. Programming Remote Keyless Entry Transmitters (Vehicles in Inventory) Important: All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made or the RCDLR module has been reprogrammed, all learned transmitters are erased. Up to 8 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. Program remote keyless entry transmitters. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 201 2. Select Next Available Slot. Follow the on-screen instructions. Simultaneously hold the LOCK and UNLOCK buttons on the keyless entry transmitter to program. 3. When all the desired transmitters have been programmed, exit the vehicle and operate the transmitter functions in order to verify correct system operation. Programming Remote Keyless Entry Transmitters (Sold Vehicles) Important: Make several copies of the programming instructions if required. Some customers may not bring all of their remote keyless entry transmitters to your dealership for programming. Vehicles are sold with two transmitters. However, customers have the option to purchase additional transmitters. Ensure that customers understand that all of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at one time in order to function properly. Program the transmitters that the customer provides to you using a scan tool. Inform the customer that all of the remaining transmitters will not function properly until they are programmed. Customers must program all of their transmitters, including the transmitters programmed at your dealership, at one time, using the driver information center (DIC) programming method. Inform customers to locate and program their transmitters using the procedure provided. This procedure is also published in the owner manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 202 Remote Control Door Lock Receiver (RCDLR) (With RPO Codes AP3/AP8) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 203 Keyless Entry Module: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT (EXCEPT AVALANCHE/ESCALADE EXT) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations Top Of The I/P Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Control Module: Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 211 Under The Front Passenger Seat Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 212 Parking Assist Control Module: Diagrams Object Alarm Module C1 (With RPO Code UD7) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 213 Object Alarm Module C2 (With RPO Code UD7) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 214 Parking Assist Control Module: Service and Repair OBJECT ALARM MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 223 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 224 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 225 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 231 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 232 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 233 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 09-08-64-004 > Mar > 09 > Restraints - Side Air Bag Deploys If Door Is Slammed Impact Sensor: All Technical Service Bulletins Restraints - Side Air Bag Deploys If Door Is Slammed TECHNICAL Bulletin No.: 09-08-64-004 Date: March 03, 2009 Subject: Side Air Bag Function (Apply Foam to Door) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Suburban, Tahoe 2007-2008 GMC Yukon Models Attention: If the air bag has been deployed, contact a GM Engineer for further information prior to repairing the vehicle. Condition In some extremely rare cases, a customer may report that when the front or rear side door is closed with extreme or unusual force, the side air bag may deploy. In these cases, the engine must be running. If the air bag has been deployed, contact a GM Engineer for further information prior to repairing the vehicle. Correction Important: Complete the side door repair steps below, then proceed to side air bag replacement following SI. 1. Remove the side door trim and water deflector. 2. Inspect all of the components in the door to make sure that they are fastened or routed properly before proceeding to step 3. 3. If you have not found anything loose or misrouted inside the door, add additional Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124, or 3M Automix P/N 8463. Run a continuous, thick bead (shown above) the entire length between the door outer panel and the top edge of inner safety beam. Make multiple passes behind the side impact sensor portion of the beam as required to fill in any gaps. 4. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124, or 3M Automix P/N 8463, in a continuous bead the entire length between the beltline reinforcement and the door outer panel. 5. Install the side door trim and water deflector. Parts Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 09-08-64-004 > Mar > 09 > Restraints - Side Air Bag Deploys If Door Is Slammed > Page 239 Warranty Information Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 08-09-41-008A > Feb > 09 > SRS - DTC's B0083/B0084 After Impact Sensor Replacement Impact Sensor: All Technical Service Bulletins SRS - DTC's B0083/B0084 After Impact Sensor Replacement INFORMATION Bulletin No.: 08-09-41-008A Date: February 02, 2009 Subject: Bumper Bar and Inflatable Restraint Front End Sensor Design Change and DTC B0083 or B0084 Set After Inflatable Restraint Front End Sensor (EFS) Has Been Replaced Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon XL, Yukon Denali Supercede: This bulletin is being revised to correct the breakpoint date and change an impact bar part number. Please discard Corporate Bulletin Number 08-09-41-008 (Section 09 - Restraints). This bulletin is being issued to inform dealers about the availability of two different types of Inflatable Restraint Front End Sensors (EFS), Front Bumper Impact Bars, SDM Operating System and SDM Calibrations on vehicles listed above. A running change was made to the front bumper bar, Inflatable Restraint Front End sensor, SDM operating system and SDM System calibration on 9/17/2007. Vehicles built before 9/17/2007 are the first design and vehicles built after 9/17/2007 are the second design. The front bumper bar for the second design does not have a knee bracket. If the first and second design Inflatable Restraint Front End Sensors, SDM Operating System or SDM System calibrations are mixed, DTC B0083 or B0084 may set. Normal diagnostics will not identify the parts/software incompatibility. Important: The two designs are not compatible with each other (parts or calibration). It is important to verify when the vehicle was built and install the correct parts and software in the vehicle. The parts catalog reflects the part changes and SPS Programming reflects the calibration changes. Please note the following: FOR SENSOR REPLACEMENT ONLY ^ Any time a vehicle (2007 or 2008) comes in for ONLY a problem that requires the replacement of an Inflatable Restraint Front End Sensor (EFS), the sensor should be replaced with the same design. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 08-09-41-008A > Feb > 09 > SRS - DTC's B0083/B0084 After Impact Sensor Replacement > Page 244 ^ Refer to the table above for correct P/N to update the SDM Operating System and SDM System Calibration using SPS. FOR BUMPER REPLACEMENT ^ When bumper bar replacement is required on any 2007 and 2008 vehicle, refer to the table for the correct P/N. ^ For vehicles built after 9/17/2007, replace the Inflatable Restraint Front End Sensor (EFS) with P/N 25896408 (2nd design). ^ Verify the SDM calibration P/N, which is dependent upon the RPO option and build date (see table). If the vehicle comes in with the air bag deployed, all appropriate service protocols/bulletins need to be followed, including the ones above. The table shows what part numbers and calibration are compatible with each other. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 09-08-64-004 > Mar > 09 > Restraints - Side Air Bag Deploys If Door Is Slammed > Page 250 Warranty Information Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 08-09-41-008A > Feb > 09 > SRS - DTC's B0083/B0084 After Impact Sensor Replacement > Page 255 ^ Refer to the table above for correct P/N to update the SDM Operating System and SDM System Calibration using SPS. FOR BUMPER REPLACEMENT ^ When bumper bar replacement is required on any 2007 and 2008 vehicle, refer to the table for the correct P/N. ^ For vehicles built after 9/17/2007, replace the Inflatable Restraint Front End Sensor (EFS) with P/N 25896408 (2nd design). ^ Verify the SDM calibration P/N, which is dependent upon the RPO option and build date (see table). If the vehicle comes in with the air bag deployed, all appropriate service protocols/bulletins need to be followed, including the ones above. The table shows what part numbers and calibration are compatible with each other. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. Door Module: Customer Interest Electrical - Power Locks/Windows/Courtesy Lamps Inop. Bulletin No.: 06-08-64-014A Date: July 20, 2006 TECHNICAL Subject: Door Locks, Power Windows, Door Courtesy Lamps, Heated/Cooled Seat Indicators Inoperative (Reprogram Driver & Passenger Door Switches) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon Supercede: This bulletin is being revised to include the Lucerne and DTS models. Please discard Corporate Bulletin Number 06-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ Front Door Locks Inoperative ^ Passenger Power Window Inoperative ^ Door Courtesy Lamps Inoperative ^ Heated/Cooled Seat Indicators Inoperative ^ Or any other driver or passenger door function issue that can be resolved by an ignition cycle. Customers may also comment that a vehicle ignition cycle typically cures the symptoms. Cause The cause of these conditions may be due to a software anomaly within the driver and passenger door switches. Correction DO NOT REPLACE THE DRIVER DOOR SWITCH OR PASSENGER DOOR SWITCH. Using SPS and Pass-Thru method, reprogram the driver door switch (DDS) and passenger door switch (PDS) with updated software calibrations. These new service calibrations were released with TIS satellite data update version 2.75 / 2006. As always, make sure your Tech 2(R) is updated with the latest software version. After the reprogramming is completed, check and clear all DTCs that may have set as a result of the programming process. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. > Page 265 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Module: > 08-08-64-013 > Aug > 08 > Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Module: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. Door Module: All Technical Service Bulletins Electrical - Power Locks/Windows/Courtesy Lamps Inop. Bulletin No.: 06-08-64-014A Date: July 20, 2006 TECHNICAL Subject: Door Locks, Power Windows, Door Courtesy Lamps, Heated/Cooled Seat Indicators Inoperative (Reprogram Driver & Passenger Door Switches) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon Supercede: This bulletin is being revised to include the Lucerne and DTS models. Please discard Corporate Bulletin Number 06-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ Front Door Locks Inoperative ^ Passenger Power Window Inoperative ^ Door Courtesy Lamps Inoperative ^ Heated/Cooled Seat Indicators Inoperative ^ Or any other driver or passenger door function issue that can be resolved by an ignition cycle. Customers may also comment that a vehicle ignition cycle typically cures the symptoms. Cause The cause of these conditions may be due to a software anomaly within the driver and passenger door switches. Correction DO NOT REPLACE THE DRIVER DOOR SWITCH OR PASSENGER DOOR SWITCH. Using SPS and Pass-Thru method, reprogram the driver door switch (DDS) and passenger door switch (PDS) with updated software calibrations. These new service calibrations were released with TIS satellite data update version 2.75 / 2006. As always, make sure your Tech 2(R) is updated with the latest software version. After the reprogramming is completed, check and clear all DTCs that may have set as a result of the programming process. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Module: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. > Page 275 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Module: > 08-08-64-013 > Aug > 08 > Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions Door Module: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 285 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 287 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 290 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Door Module: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 292 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 293 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 296 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 297 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 298 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 299 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 301 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 302 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 303 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 305 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 306 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 309 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 310 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 311 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 312 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 313 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 314 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 315 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 316 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 317 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 318 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 319 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 320 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 321 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 322 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 323 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 324 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 325 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 326 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 327 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 328 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 329 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 330 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 331 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 332 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 333 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 334 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 335 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 336 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 337 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 338 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 339 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 340 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 341 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 342 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 343 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 344 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 345 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 346 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 347 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 348 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 349 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 350 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 351 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 352 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 353 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 354 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 355 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 356 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 357 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 358 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 359 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 360 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 361 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 362 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 363 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 364 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 365 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 366 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 367 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 368 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 369 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 370 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 371 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 372 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 373 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming Technical Service Bulletin # 07007C Date: 070215 Campaign - Keyless Entry Transmitter/Module Programming Subject: Service Update for Inventory and Customer Vehicles-Remote Keyless Entry (RKE) Inoperative and Battery Rundown - Expires with Base Warranty # 07007C - (02/15/2007) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon XL 2007 Pontiac Torrent THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07007AB ISSUED FEBRUARY 2007. TECHNICIAN MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICIANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON TO ASSIST IN IMPROVING PERFORMANCE AND REDUCE PROGRAMMING TIME IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED USING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. This bulletin provides a service procedure for reprogramming the remote control door lock receiver (RCDLR) and the remote keyless entry transmitter (FOB) on certain 2006-2007 Buick Lucerne; 2006-2007 Cadillac DTS; 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX; 2006-2007 Chevrolet Impala, Monte Carlo; 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe; 2007 GMC Yukon, Yukon XL; and 2007 Pontiac Torrent vehicles. On these vehicles, the RKE may become inoperative. Also, for the 2007 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL vehicles (GMT900 Utility) only, this bulletin provides a service procedure for reprogramming the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 382 Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Claim Information Programming Remote Keyless Entry Transmitters Using the Driver Information Center (DIC) All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at the same time, including the one programmed at the dealership. Those transmitters not programmed at the same time will not function properly. Follow the procedure below for programming. This procedure is also published in the Owner Manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 383 RELEARN REMOTE KEY The Driver Information Center (DIC) display allows you to match the remote keyless entry transmitter to your vehicle. To match a remote keyless entry transmitter to your vehicle do the following: 1. Press the vehicle information button until RELEARN REMOTE KEY displays. 2. Press the set/reset button. 3. Press and hold the lock and unlock buttons on the first transmitter at the same time for approximately 15 seconds. On vehicles with memory recall seats, the first transmitter learned will match driver 1 and the second will match driver 2. 4. To match additional transmitters at this time, repeat step 3 with each new transmitter. Each vehicle can have a maximum of eight transmitters matched to it. 5. To exit the programming mode, you must cycle the key to the OFF/LOCK position. Disclaimer Service Procedure Important: Technicians may experience low performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicans may notice the lower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if low performance is experienced. Important: This bulletin contains two reprogramming procedures, 1) reprogramming of the BCM, and 2) reprogramming of the RCDLR. Not all vehicles require reprogramming of both. ^ The Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon and Yukon XL vehicles require the BCM and RCDLR reprogramming. ^ The Buick Lucerne; Cadillac DTS; Chevrolet Impala, Monte Carlo; Chevrolet Equinox; and Pontiac Torrent require only the RCDLR reprogramming - DO NOT ATTEMPT TO REPROGRAM THE BCM ON THESE VEHICLES. Body Control Module Reprogramming - For Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL ONLY: Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 384 Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery. Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controlers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech2(R). 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2(R). 14. Go into diagnostics and check for DTC codes. 15. Clear all codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 385 Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the IPC 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. 16. Proceed to RCDLR Reprogramming. RCDLR Reprogramming - For All Vehicles Important: The Tech 2 diagnostic tool must be updated with version 27.003 or later for reprogramming the Remote Control Door Lock Receiver (RCDLR). The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 10 for 2006 (available on 10/01/06) and on TIS DVD version 10/2006 or later that was mailed to dealers on October 18, 2006. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for Remote Control Door Lock Receiver (RCDLR) Important: The Copy and Paste procedure in Step 7 does not apply to 2006 Lucerne vehicles. Please refer to the appropriate Tire Pressure Monitor reset procedure in SI. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. 2. Turn on the Tech2(R). 3. Build the vehicle using the Tech 2(R). 4. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 5. Write down all four Pressure Sensor IDs on a sheet of paper. 6. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. Important: If "Replace Module Per Service Manual" message appears on the Tech 2 during this procedure, ignore the message and press the "Exit" key on the Tech 2 and proceed to the next step. Do NOT replace the module. 7. Run the Copy and Paste TPM Information Procedure (FO: Step 1). Follow the on-screen instructions: Turn the ignition to the ON position with the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 386 engine OFF. 8. Turn off the Tech 2. 9. Turn on the Tech2. 10. Connect the Tech 2 to the vehicle and the TIS terminal. 11. On the TIS terminal go into SPS Programming. 12. Select Pass Thru programming. 13. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen: 13.1. Scroll down in the top box and select RCDLR (Remote Control Door Lock Receiver). 13.2. In the lower box select Normal. 13.3. Select Next. Important: Some vehicles will require additional selections in the module field before you can proceed and the "Next" button is functional. 14. When the Calibration Screen displays, select calibration 25808841 for vehicles that are NOT equipped with the remote start feature or calibration 25808842 for vehicles that are equipped with the remote start feature. After selecting a calibration, select Next. 15. Follow the on-screen prompts until programming is completed. 16. When programming is complete: 16.1. Turn off Tech2. 16.2. Turn the ignition switch to the OFF position. 17. Wait 30 seconds~. 18. Turn the ignition switch to the ON position with engine OFF. 19. Turn on the Tech 2. 20. Build the vehicle using the Tech 2. 21. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. 22. Run the Copy and Paste TPM Information Procedure (F1: Step 2). 23. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 24. Verify that the four Pressure Sensor IDs match those that were recorded in Step 5. 25. Go into diagnostics and check for DTC codes. 26. Clear all codes. Programming Remote Keyless Entry Transmitters (Vehicles in Inventory) Important: All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made or the RCDLR module has been reprogrammed, all learned transmitters are erased. Up to 8 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. Program remote keyless entry transmitters. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Recalls: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 387 2. Select Next Available Slot. Follow the on-screen instructions. Simultaneously hold the LOCK and UNLOCK buttons on the keyless entry transmitter to program. 3. When all the desired transmitters have been programmed, exit the vehicle and operate the transmitter functions in order to verify correct system operation. Programming Remote Keyless Entry Transmitters (Sold Vehicles) Important: Make several copies of the programming instructions if required. Some customers may not bring all of their remote keyless entry transmitters to your dealership for programming. Vehicles are sold with two transmitters. However, customers have the option to purchase additional transmitters. Ensure that customers understand that all of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at one time in order to function properly. Program the transmitters that the customer provides to you using a scan tool. Inform the customer that all of the remaining transmitters will not function properly until they are programmed. Customers must program all of their transmitters, including the transmitters programmed at your dealership, at one time, using the driver information center (DIC) programming method. Inform customers to locate and program their transmitters using the procedure provided. This procedure is also published in the owner manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed Keyless Entry Module: Customer Interest Keyless Systems - Poor Range/TPM Message Displayed TECHNICAL Bulletin No.: 06-08-52-002G Date: November 24, 2008 Subject: Remote Keyless Entry (RKE) Inoperative, Poor Range, Tire Pressure Monitor (TPM) Message Displayed, Remote Vehicle Start (RVS) (Replace RKE Transmitters and Reprogram Remote Control Door Lock Receiver (RCDLR)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007 Pontiac Torrent Supercede: This bulletin is being revised to update the Part Information. Please discard Corporate Bulletin Number 06-08-52-002F (Section 08 - Body & Accessories). Condition Some customers may comment about one or more of the following conditions: ^ The remote keyless entry (RKE) transmitters will not program, function and/or the RKE transmitter low battery message is displayed. ^ The Service Tire Monitor System message is displayed. ^ The new RKE transmitters cannot be programmed. ^ The remote keyless entry (RKE) and/or remote vehicle start (RVS) transmitter has poor range. Cause Any of these concerns may be caused by an internal fault with the transmitters and/or the RCDLR software/hardware. Correction Important: Check VIS to determine if Inventory Upgrade 07007 applies and has been completed. If the vehicle is listed in the Inventory Upgrade, and the upgrade has not been performed, complete the Inventory Upgrade before proceeding with this bulletin. DO NOT REPLACE THE BCM OR RADIO ANTENNA MODULE. Complete the following repair procedures: Important: When programming a new or existing RCDLR, the programming instructions in SI must be followed. ^ On vehicles equipped with Tire Pressure Monitoring (TPM), the tire type and tire pressures must be selected in the module set-up using the Tech 2(R). If this step is not performed, the RCDLR will not retain the tire pressures after the TPM system is learned. Tip: When selecting the Tire Type/Pressure, choose the appropriate selection on the Tech 2 based on psi, not kPa. ^ Relearn the TPM sensors using the J 46079 and following the procedure found in SI. ^ After the learn procedure is complete, be sure to set the tire pressures according to the information on the tire placard. Important: If the Inventory upgrade 07007 has been performed, skip the initial RCDLR programming step #1 and proceed to step # 2. Reprogram the RCDLR with the latest software update available through TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 393 Important: New transmitters are identified by a star on the back of the transmitter. It is important to verify that the replacement transmitters have a star on the back. 1. Replace both Remote Keyless Entry transmitters. 2. Program the transmitters using the procedure listed in SI. 3. Perform the following steps in the exact order: 1. Remove the key from the ignition. 2. Open and close the driver's door. 3. Close all other doors/trunk/liftgates. 4. Wait 5 minutes. 5. Press the Unlock Button and verify that the doors all unlock. ^ If the customer's concerns are corrected, no further repairs are required. ^ If the customer's concerns are NOT corrected, proceed with step 5. Important: In most cases, steps 1-3 will correct the customer's concern. In a few cases, it may be necessary to replace the RCDLR. 4. If the customer's concern is still present, replace the RCDLR. 5. Program the RCDLR with the latest software update available through TIS2WEB. 6. Reprogram both Remote Keyless Entry Transmitters. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 394 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed Keyless Entry Module: All Technical Service Bulletins Keyless Systems - Poor Range/TPM Message Displayed TECHNICAL Bulletin No.: 06-08-52-002G Date: November 24, 2008 Subject: Remote Keyless Entry (RKE) Inoperative, Poor Range, Tire Pressure Monitor (TPM) Message Displayed, Remote Vehicle Start (RVS) (Replace RKE Transmitters and Reprogram Remote Control Door Lock Receiver (RCDLR)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007 Pontiac Torrent Supercede: This bulletin is being revised to update the Part Information. Please discard Corporate Bulletin Number 06-08-52-002F (Section 08 - Body & Accessories). Condition Some customers may comment about one or more of the following conditions: ^ The remote keyless entry (RKE) transmitters will not program, function and/or the RKE transmitter low battery message is displayed. ^ The Service Tire Monitor System message is displayed. ^ The new RKE transmitters cannot be programmed. ^ The remote keyless entry (RKE) and/or remote vehicle start (RVS) transmitter has poor range. Cause Any of these concerns may be caused by an internal fault with the transmitters and/or the RCDLR software/hardware. Correction Important: Check VIS to determine if Inventory Upgrade 07007 applies and has been completed. If the vehicle is listed in the Inventory Upgrade, and the upgrade has not been performed, complete the Inventory Upgrade before proceeding with this bulletin. DO NOT REPLACE THE BCM OR RADIO ANTENNA MODULE. Complete the following repair procedures: Important: When programming a new or existing RCDLR, the programming instructions in SI must be followed. ^ On vehicles equipped with Tire Pressure Monitoring (TPM), the tire type and tire pressures must be selected in the module set-up using the Tech 2(R). If this step is not performed, the RCDLR will not retain the tire pressures after the TPM system is learned. Tip: When selecting the Tire Type/Pressure, choose the appropriate selection on the Tech 2 based on psi, not kPa. ^ Relearn the TPM sensors using the J 46079 and following the procedure found in SI. ^ After the learn procedure is complete, be sure to set the tire pressures according to the information on the tire placard. Important: If the Inventory upgrade 07007 has been performed, skip the initial RCDLR programming step #1 and proceed to step # 2. Reprogram the RCDLR with the latest software update available through TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 400 Important: New transmitters are identified by a star on the back of the transmitter. It is important to verify that the replacement transmitters have a star on the back. 1. Replace both Remote Keyless Entry transmitters. 2. Program the transmitters using the procedure listed in SI. 3. Perform the following steps in the exact order: 1. Remove the key from the ignition. 2. Open and close the driver's door. 3. Close all other doors/trunk/liftgates. 4. Wait 5 minutes. 5. Press the Unlock Button and verify that the doors all unlock. ^ If the customer's concerns are corrected, no further repairs are required. ^ If the customer's concerns are NOT corrected, proceed with step 5. Important: In most cases, steps 1-3 will correct the customer's concern. In a few cases, it may be necessary to replace the RCDLR. 4. If the customer's concern is still present, replace the RCDLR. 5. Program the RCDLR with the latest software update available through TIS2WEB. 6. Reprogram both Remote Keyless Entry Transmitters. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 401 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming Technical Service Bulletin # 07007C Date: 070215 Campaign - Keyless Entry Transmitter/Module Programming Subject: Service Update for Inventory and Customer Vehicles-Remote Keyless Entry (RKE) Inoperative and Battery Rundown - Expires with Base Warranty # 07007C - (02/15/2007) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon XL 2007 Pontiac Torrent THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07007AB ISSUED FEBRUARY 2007. TECHNICIAN MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICIANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON TO ASSIST IN IMPROVING PERFORMANCE AND REDUCE PROGRAMMING TIME IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED USING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. This bulletin provides a service procedure for reprogramming the remote control door lock receiver (RCDLR) and the remote keyless entry transmitter (FOB) on certain 2006-2007 Buick Lucerne; 2006-2007 Cadillac DTS; 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX; 2006-2007 Chevrolet Impala, Monte Carlo; 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe; 2007 GMC Yukon, Yukon XL; and 2007 Pontiac Torrent vehicles. On these vehicles, the RKE may become inoperative. Also, for the 2007 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL vehicles (GMT900 Utility) only, this bulletin provides a service procedure for reprogramming the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 406 Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Claim Information Programming Remote Keyless Entry Transmitters Using the Driver Information Center (DIC) All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at the same time, including the one programmed at the dealership. Those transmitters not programmed at the same time will not function properly. Follow the procedure below for programming. This procedure is also published in the Owner Manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 407 RELEARN REMOTE KEY The Driver Information Center (DIC) display allows you to match the remote keyless entry transmitter to your vehicle. To match a remote keyless entry transmitter to your vehicle do the following: 1. Press the vehicle information button until RELEARN REMOTE KEY displays. 2. Press the set/reset button. 3. Press and hold the lock and unlock buttons on the first transmitter at the same time for approximately 15 seconds. On vehicles with memory recall seats, the first transmitter learned will match driver 1 and the second will match driver 2. 4. To match additional transmitters at this time, repeat step 3 with each new transmitter. Each vehicle can have a maximum of eight transmitters matched to it. 5. To exit the programming mode, you must cycle the key to the OFF/LOCK position. Disclaimer Service Procedure Important: Technicians may experience low performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicans may notice the lower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if low performance is experienced. Important: This bulletin contains two reprogramming procedures, 1) reprogramming of the BCM, and 2) reprogramming of the RCDLR. Not all vehicles require reprogramming of both. ^ The Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon and Yukon XL vehicles require the BCM and RCDLR reprogramming. ^ The Buick Lucerne; Cadillac DTS; Chevrolet Impala, Monte Carlo; Chevrolet Equinox; and Pontiac Torrent require only the RCDLR reprogramming - DO NOT ATTEMPT TO REPROGRAM THE BCM ON THESE VEHICLES. Body Control Module Reprogramming - For Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL ONLY: Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 408 Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery. Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controlers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech2(R). 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2(R). 14. Go into diagnostics and check for DTC codes. 15. Clear all codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 409 Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the IPC 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. 16. Proceed to RCDLR Reprogramming. RCDLR Reprogramming - For All Vehicles Important: The Tech 2 diagnostic tool must be updated with version 27.003 or later for reprogramming the Remote Control Door Lock Receiver (RCDLR). The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 10 for 2006 (available on 10/01/06) and on TIS DVD version 10/2006 or later that was mailed to dealers on October 18, 2006. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for Remote Control Door Lock Receiver (RCDLR) Important: The Copy and Paste procedure in Step 7 does not apply to 2006 Lucerne vehicles. Please refer to the appropriate Tire Pressure Monitor reset procedure in SI. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. 2. Turn on the Tech2(R). 3. Build the vehicle using the Tech 2(R). 4. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 5. Write down all four Pressure Sensor IDs on a sheet of paper. 6. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. Important: If "Replace Module Per Service Manual" message appears on the Tech 2 during this procedure, ignore the message and press the "Exit" key on the Tech 2 and proceed to the next step. Do NOT replace the module. 7. Run the Copy and Paste TPM Information Procedure (FO: Step 1). Follow the on-screen instructions: Turn the ignition to the ON position with the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 410 engine OFF. 8. Turn off the Tech 2. 9. Turn on the Tech2. 10. Connect the Tech 2 to the vehicle and the TIS terminal. 11. On the TIS terminal go into SPS Programming. 12. Select Pass Thru programming. 13. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen: 13.1. Scroll down in the top box and select RCDLR (Remote Control Door Lock Receiver). 13.2. In the lower box select Normal. 13.3. Select Next. Important: Some vehicles will require additional selections in the module field before you can proceed and the "Next" button is functional. 14. When the Calibration Screen displays, select calibration 25808841 for vehicles that are NOT equipped with the remote start feature or calibration 25808842 for vehicles that are equipped with the remote start feature. After selecting a calibration, select Next. 15. Follow the on-screen prompts until programming is completed. 16. When programming is complete: 16.1. Turn off Tech2. 16.2. Turn the ignition switch to the OFF position. 17. Wait 30 seconds~. 18. Turn the ignition switch to the ON position with engine OFF. 19. Turn on the Tech 2. 20. Build the vehicle using the Tech 2. 21. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. 22. Run the Copy and Paste TPM Information Procedure (F1: Step 2). 23. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 24. Verify that the four Pressure Sensor IDs match those that were recorded in Step 5. 25. Go into diagnostics and check for DTC codes. 26. Clear all codes. Programming Remote Keyless Entry Transmitters (Vehicles in Inventory) Important: All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made or the RCDLR module has been reprogrammed, all learned transmitters are erased. Up to 8 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. Program remote keyless entry transmitters. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 411 2. Select Next Available Slot. Follow the on-screen instructions. Simultaneously hold the LOCK and UNLOCK buttons on the keyless entry transmitter to program. 3. When all the desired transmitters have been programmed, exit the vehicle and operate the transmitter functions in order to verify correct system operation. Programming Remote Keyless Entry Transmitters (Sold Vehicles) Important: Make several copies of the programming instructions if required. Some customers may not bring all of their remote keyless entry transmitters to your dealership for programming. Vehicles are sold with two transmitters. However, customers have the option to purchase additional transmitters. Ensure that customers understand that all of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at one time in order to function properly. Program the transmitters that the customer provides to you using a scan tool. Inform the customer that all of the remaining transmitters will not function properly until they are programmed. Customers must program all of their transmitters, including the transmitters programmed at your dealership, at one time, using the driver information center (DIC) programming method. Inform customers to locate and program their transmitters using the procedure provided. This procedure is also published in the owner manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed Keyless Entry Module: All Technical Service Bulletins Keyless Systems - Poor Range/TPM Message Displayed TECHNICAL Bulletin No.: 06-08-52-002G Date: November 24, 2008 Subject: Remote Keyless Entry (RKE) Inoperative, Poor Range, Tire Pressure Monitor (TPM) Message Displayed, Remote Vehicle Start (RVS) (Replace RKE Transmitters and Reprogram Remote Control Door Lock Receiver (RCDLR)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007 Pontiac Torrent Supercede: This bulletin is being revised to update the Part Information. Please discard Corporate Bulletin Number 06-08-52-002F (Section 08 - Body & Accessories). Condition Some customers may comment about one or more of the following conditions: ^ The remote keyless entry (RKE) transmitters will not program, function and/or the RKE transmitter low battery message is displayed. ^ The Service Tire Monitor System message is displayed. ^ The new RKE transmitters cannot be programmed. ^ The remote keyless entry (RKE) and/or remote vehicle start (RVS) transmitter has poor range. Cause Any of these concerns may be caused by an internal fault with the transmitters and/or the RCDLR software/hardware. Correction Important: Check VIS to determine if Inventory Upgrade 07007 applies and has been completed. If the vehicle is listed in the Inventory Upgrade, and the upgrade has not been performed, complete the Inventory Upgrade before proceeding with this bulletin. DO NOT REPLACE THE BCM OR RADIO ANTENNA MODULE. Complete the following repair procedures: Important: When programming a new or existing RCDLR, the programming instructions in SI must be followed. ^ On vehicles equipped with Tire Pressure Monitoring (TPM), the tire type and tire pressures must be selected in the module set-up using the Tech 2(R). If this step is not performed, the RCDLR will not retain the tire pressures after the TPM system is learned. Tip: When selecting the Tire Type/Pressure, choose the appropriate selection on the Tech 2 based on psi, not kPa. ^ Relearn the TPM sensors using the J 46079 and following the procedure found in SI. ^ After the learn procedure is complete, be sure to set the tire pressures according to the information on the tire placard. Important: If the Inventory upgrade 07007 has been performed, skip the initial RCDLR programming step #1 and proceed to step # 2. Reprogram the RCDLR with the latest software update available through TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 417 Important: New transmitters are identified by a star on the back of the transmitter. It is important to verify that the replacement transmitters have a star on the back. 1. Replace both Remote Keyless Entry transmitters. 2. Program the transmitters using the procedure listed in SI. 3. Perform the following steps in the exact order: 1. Remove the key from the ignition. 2. Open and close the driver's door. 3. Close all other doors/trunk/liftgates. 4. Wait 5 minutes. 5. Press the Unlock Button and verify that the doors all unlock. ^ If the customer's concerns are corrected, no further repairs are required. ^ If the customer's concerns are NOT corrected, proceed with step 5. Important: In most cases, steps 1-3 will correct the customer's concern. In a few cases, it may be necessary to replace the RCDLR. 4. If the customer's concern is still present, replace the RCDLR. 5. Program the RCDLR with the latest software update available through TIS2WEB. 6. Reprogram both Remote Keyless Entry Transmitters. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 06-08-52-002G > Nov > 08 > Keyless Systems - Poor Range/TPM Message Displayed > Page 418 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming Technical Service Bulletin # 07007C Date: 070215 Campaign - Keyless Entry Transmitter/Module Programming Subject: Service Update for Inventory and Customer Vehicles-Remote Keyless Entry (RKE) Inoperative and Battery Rundown - Expires with Base Warranty # 07007C - (02/15/2007) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe 2007 GMC Yukon, Yukon XL 2007 Pontiac Torrent THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07007AB ISSUED FEBRUARY 2007. TECHNICIAN MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICIANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON TO ASSIST IN IMPROVING PERFORMANCE AND REDUCE PROGRAMMING TIME IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED USING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. This bulletin provides a service procedure for reprogramming the remote control door lock receiver (RCDLR) and the remote keyless entry transmitter (FOB) on certain 2006-2007 Buick Lucerne; 2006-2007 Cadillac DTS; 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX; 2006-2007 Chevrolet Impala, Monte Carlo; 2007 Chevrolet Avalanche, Equinox, Suburban, Tahoe; 2007 GMC Yukon, Yukon XL; and 2007 Pontiac Torrent vehicles. On these vehicles, the RKE may become inoperative. Also, for the 2007 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL vehicles (GMT900 Utility) only, this bulletin provides a service procedure for reprogramming the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 424 Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Claim Information Programming Remote Keyless Entry Transmitters Using the Driver Information Center (DIC) All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at the same time, including the one programmed at the dealership. Those transmitters not programmed at the same time will not function properly. Follow the procedure below for programming. This procedure is also published in the Owner Manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 425 RELEARN REMOTE KEY The Driver Information Center (DIC) display allows you to match the remote keyless entry transmitter to your vehicle. To match a remote keyless entry transmitter to your vehicle do the following: 1. Press the vehicle information button until RELEARN REMOTE KEY displays. 2. Press the set/reset button. 3. Press and hold the lock and unlock buttons on the first transmitter at the same time for approximately 15 seconds. On vehicles with memory recall seats, the first transmitter learned will match driver 1 and the second will match driver 2. 4. To match additional transmitters at this time, repeat step 3 with each new transmitter. Each vehicle can have a maximum of eight transmitters matched to it. 5. To exit the programming mode, you must cycle the key to the OFF/LOCK position. Disclaimer Service Procedure Important: Technicians may experience low performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicans may notice the lower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if low performance is experienced. Important: This bulletin contains two reprogramming procedures, 1) reprogramming of the BCM, and 2) reprogramming of the RCDLR. Not all vehicles require reprogramming of both. ^ The Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon and Yukon XL vehicles require the BCM and RCDLR reprogramming. ^ The Buick Lucerne; Cadillac DTS; Chevrolet Impala, Monte Carlo; Chevrolet Equinox; and Pontiac Torrent require only the RCDLR reprogramming - DO NOT ATTEMPT TO REPROGRAM THE BCM ON THESE VEHICLES. Body Control Module Reprogramming - For Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe; and GMC Yukon, Yukon XL ONLY: Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 426 Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery. Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controlers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech2(R). 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2(R). 14. Go into diagnostics and check for DTC codes. 15. Clear all codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 427 Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the IPC 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. 16. Proceed to RCDLR Reprogramming. RCDLR Reprogramming - For All Vehicles Important: The Tech 2 diagnostic tool must be updated with version 27.003 or later for reprogramming the Remote Control Door Lock Receiver (RCDLR). The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 10 for 2006 (available on 10/01/06) and on TIS DVD version 10/2006 or later that was mailed to dealers on October 18, 2006. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for Remote Control Door Lock Receiver (RCDLR) Important: The Copy and Paste procedure in Step 7 does not apply to 2006 Lucerne vehicles. Please refer to the appropriate Tire Pressure Monitor reset procedure in SI. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. 2. Turn on the Tech2(R). 3. Build the vehicle using the Tech 2(R). 4. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 5. Write down all four Pressure Sensor IDs on a sheet of paper. 6. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. Important: If "Replace Module Per Service Manual" message appears on the Tech 2 during this procedure, ignore the message and press the "Exit" key on the Tech 2 and proceed to the next step. Do NOT replace the module. 7. Run the Copy and Paste TPM Information Procedure (FO: Step 1). Follow the on-screen instructions: Turn the ignition to the ON position with the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 428 engine OFF. 8. Turn off the Tech 2. 9. Turn on the Tech2. 10. Connect the Tech 2 to the vehicle and the TIS terminal. 11. On the TIS terminal go into SPS Programming. 12. Select Pass Thru programming. 13. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen: 13.1. Scroll down in the top box and select RCDLR (Remote Control Door Lock Receiver). 13.2. In the lower box select Normal. 13.3. Select Next. Important: Some vehicles will require additional selections in the module field before you can proceed and the "Next" button is functional. 14. When the Calibration Screen displays, select calibration 25808841 for vehicles that are NOT equipped with the remote start feature or calibration 25808842 for vehicles that are equipped with the remote start feature. After selecting a calibration, select Next. 15. Follow the on-screen prompts until programming is completed. 16. When programming is complete: 16.1. Turn off Tech2. 16.2. Turn the ignition switch to the OFF position. 17. Wait 30 seconds~. 18. Turn the ignition switch to the ON position with engine OFF. 19. Turn on the Tech 2. 20. Build the vehicle using the Tech 2. 21. Using the Tech 2, navigate to Vehicle Control Systems / Module Setup / Remote Control Door Lock Receiver. 22. Run the Copy and Paste TPM Information Procedure (F1: Step 2). 23. Using the Tech 2, navigate to Vehicle Control Systems / Module ID Information / Remote Control Door Lock Receiver / Tire Information. 24. Verify that the four Pressure Sensor IDs match those that were recorded in Step 5. 25. Go into diagnostics and check for DTC codes. 26. Clear all codes. Programming Remote Keyless Entry Transmitters (Vehicles in Inventory) Important: All of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made or the RCDLR module has been reprogrammed, all learned transmitters are erased. Up to 8 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. Program remote keyless entry transmitters. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 07007C > Feb > 07 > Campaign - Keyless Entry Transmitter/Module Programming > Page 429 2. Select Next Available Slot. Follow the on-screen instructions. Simultaneously hold the LOCK and UNLOCK buttons on the keyless entry transmitter to program. 3. When all the desired transmitters have been programmed, exit the vehicle and operate the transmitter functions in order to verify correct system operation. Programming Remote Keyless Entry Transmitters (Sold Vehicles) Important: Make several copies of the programming instructions if required. Some customers may not bring all of their remote keyless entry transmitters to your dealership for programming. Vehicles are sold with two transmitters. However, customers have the option to purchase additional transmitters. Ensure that customers understand that all of the transmitters that are to be recognized by the remote control door lock receiver (RCDLR) must be programmed at one time in order to function properly. Program the transmitters that the customer provides to you using a scan tool. Inform the customer that all of the remaining transmitters will not function properly until they are programmed. Customers must program all of their transmitters, including the transmitters programmed at your dealership, at one time, using the driver information center (DIC) programming method. Inform customers to locate and program their transmitters using the procedure provided. This procedure is also published in the owner manual. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 430 Remote Control Door Lock Receiver (RCDLR) (With RPO Codes AP3/AP8) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 431 Keyless Entry Module: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT (EXCEPT AVALANCHE/ESCALADE EXT) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams Memory Positioning Module: Diagrams Memory Seat Module C1 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 435 Memory Seat Module C2 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 436 Memory Seat Module C3 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 437 Memory Seat Module C4 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 438 Memory Seat Module C5 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 439 Memory Seat Module C6 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 440 Memory Seat Module C7 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 441 Memory Positioning Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Page 442 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations Driver Seat Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 446 Power Seat Control Module: Diagrams Memory Seat Module C1 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 447 Memory Seat Module C2 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 448 Memory Seat Module C3 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 449 Memory Seat Module C4 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 450 Memory Seat Module C5 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 451 Memory Seat Module C6 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 452 Memory Seat Module C7 (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 453 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 454 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C1 (With RPO Code E61) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Page 458 Power Liftgate Module C2 (With RPO Code E61) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Accessory and Liftgate Control Module Replacement Power Trunk / Liftgate Control Module: Service and Repair Accessory and Liftgate Control Module Replacement ACCESSORY AND LIFTGATE CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Accessory and Liftgate Control Module Replacement > Page 461 Power Trunk / Liftgate Control Module: Service and Repair Liftgate Close Actuator Motor Control Module Replacement LIFTGATE CLOSE ACTUATOR MOTOR CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Step / Running Board Module: > 07-08-61-004 > Mar > 07 > Body - Power Running Boards/Assist Steps Inoperative Auxiliary Step / Running Board Module: Customer Interest Body - Power Running Boards/Assist Steps Inoperative Bulletin No.: 07-08-61-004 Date: March 12, 2007 TECHNICAL Subject: Articulating Running Boards (Assist Steps) Inoperative (Reprogram Assist Step Controller) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali Built Between November 15, 2006 and January 16, 2007 (with Assist Step Controller P/N 25822021) Condition Some customers may comment that the power running boards/assist steps on the vehicle operate intermittently at times or are inoperative. The running boards may stop in mid-travel and remain there until the next key cycle. DTCs B051C22 or B051D22 may or may not have set. Cause This condition may be caused by the software in the running board/assist step controller. Correction Do not reprogram assist step controller P/Ns 25782667 and 25852622. These modules will not exhibit the condition. Reprogram the running board/assist step controller, P/N 25822021, with the new calibration. Use the Pass-Thru method for programming this controller. Reprogram the Assist Step Controller. Refer to Service Programming System (SPS) in SI for programming information, if required. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Step / Running Board Module: > 07-08-61-004 > Mar > 07 > Body - Power Running Boards/Assist Steps Inoperative Auxiliary Step / Running Board Module: All Technical Service Bulletins Body - Power Running Boards/Assist Steps Inoperative Bulletin No.: 07-08-61-004 Date: March 12, 2007 TECHNICAL Subject: Articulating Running Boards (Assist Steps) Inoperative (Reprogram Assist Step Controller) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali Built Between November 15, 2006 and January 16, 2007 (with Assist Step Controller P/N 25822021) Condition Some customers may comment that the power running boards/assist steps on the vehicle operate intermittently at times or are inoperative. The running boards may stop in mid-travel and remain there until the next key cycle. DTCs B051C22 or B051D22 may or may not have set. Cause This condition may be caused by the software in the running board/assist step controller. Correction Do not reprogram assist step controller P/Ns 25782667 and 25852622. These modules will not exhibit the condition. Reprogram the running board/assist step controller, P/N 25822021, with the new calibration. Use the Pass-Thru method for programming this controller. Reprogram the Assist Step Controller. Refer to Service Programming System (SPS) in SI for programming information, if required. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Technical Service Bulletins > Page 475 Auxiliary Step / Running Board Module: Service and Repair Assist Step Controller Replacement Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 484 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 485 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 486 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 487 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-50-017B > Feb > 10 > Electrical - No Crank/No Start/Discharged or Low Battery Seat Heater Control Module: Customer Interest Electrical - No Crank/No Start/Discharged or Low Battery TECHNICAL Bulletin No.: 09-08-50-017B Date: February 11, 2010 Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Rear Heated Seat Module) Models: 2006-2010 Cadillac DTS Built Prior to February 2, 2010 2007-2010 Cadillac Escalade, Escalade ESV 2007-2010 Chevrolet Suburban, Tahoe 2007-2010 GMC Yukon, Yukon XL Built Prior to November 30, 2009 All Equipped with Rear Heated Seat RPO KA6 Supercede: This bulletin is being revised to add build breakpoint dates. Please discard Corporate Bulletin Number 09-08-50-017A (Section 08 - Body and Accessories). Condition Some customers may comment about a no crank/no start condition or a discharged or low battery. Note This condition may be intermittent, therefore it is important to check if a revised calibration has been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the dealer. Cause This condition may be caused by the rear heated seat module (RHSM) discharging the battery by keeping the serial data bus active, which creates a cumulative continuous draw of four amps on the battery after the vehicle is shut down, until the state of charge reaches three volts. Correction Important DO NOT replace the RHSM or the battery for this concern. Reprogram the RHSM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the RHSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-50-017B > Feb > 10 > Electrical - No Crank/No Start/Discharged or Low Battery > Page 492 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 498 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 499 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 500 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 501 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-50-017B > Feb > 10 > Electrical - No Crank/No Start/Discharged or Low Battery Seat Heater Control Module: All Technical Service Bulletins Electrical - No Crank/No Start/Discharged or Low Battery TECHNICAL Bulletin No.: 09-08-50-017B Date: February 11, 2010 Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Rear Heated Seat Module) Models: 2006-2010 Cadillac DTS Built Prior to February 2, 2010 2007-2010 Cadillac Escalade, Escalade ESV 2007-2010 Chevrolet Suburban, Tahoe 2007-2010 GMC Yukon, Yukon XL Built Prior to November 30, 2009 All Equipped with Rear Heated Seat RPO KA6 Supercede: This bulletin is being revised to add build breakpoint dates. Please discard Corporate Bulletin Number 09-08-50-017A (Section 08 - Body and Accessories). Condition Some customers may comment about a no crank/no start condition or a discharged or low battery. Note This condition may be intermittent, therefore it is important to check if a revised calibration has been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the dealer. Cause This condition may be caused by the rear heated seat module (RHSM) discharging the battery by keeping the serial data bus active, which creates a cumulative continuous draw of four amps on the battery after the vehicle is shut down, until the state of charge reaches three volts. Correction Important DO NOT replace the RHSM or the battery for this concern. Reprogram the RHSM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the RHSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-50-017B > Feb > 10 > Electrical - No Crank/No Start/Discharged or Low Battery > Page 506 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-08-66-010 > Jun > 06 > Body - Squeak Noise at Rear of Vehicle Over Bumpy Roads Trunk / Liftgate Striker: All Technical Service Bulletins Body - Squeak Noise at Rear of Vehicle Over Bumpy Roads Bulletin No.: 06-08-66-010 Date: June 27, 2006 TECHNICAL Subject: Squeak Noise at Rear of Vehicle Over Bumpy Roads (Install Washer) Models: 2007 Cadillac Escalade, Escalade ESV 2007 Chevrolet Suburban, Tahoe 2007 GMC Yukon XL, Yukon Denali, Denali XL Condition Some customers may comment that there is an objectionable squeak noise at the rear of the vehicle when driving over bumpy roads. Cause The liftgate may have been built too high to the body opening, which may cause the latch to rub against the striker. Refer to the illustration above. Correction 1. Remove the liftgate striker trim. 2. Remove the striker. 3. Insert the washer under the striker. 4. Install the striker. Tighten Tighten the striker bolts to 25 (+/- 5) Nm (5.6 lb ft). 5. Install the liftgate striker trim. Parts Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-08-66-010 > Jun > 06 > Body - Squeak Noise at Rear of Vehicle Over Bumpy Roads > Page 512 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-08-66-010 > Jun > 06 > Body - Squeak Noise at Rear of Vehicle Over Bumpy Roads > Page 518 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 519 Seat Heater Control Module: Locations Rear Seats Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 520 Rear Seats Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module Seat Heater Control Module: Diagrams Climate Control Seat Module Climate Control Seat Module C1 (With RPO Code KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 523 Climate Control Seat Module C2 (With RPO Code KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 524 Climate Control Seat Module C3 (With RPO Code KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 525 Seat Heater Control Module: Diagrams Heated Seat Module - Rear Heated Seat Module - Rear C1 (With RPO Code KA6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 526 Heated Seat Module - Rear C2 (With RPO Code KA6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 527 Heated Seat Module - Rear C3 (With RPO Code KA6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 528 Heated Seat Module - Rear C4 (With RPO Code KA6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 529 Seat Heater Control Module: Diagrams Seat Back Ventilation Heat & Cool Module Seat Back Ventilation Heat & Cool Module - Driver (With RPO Code KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 530 Seat Back Ventilation Heat & Cool Module - Passenger (With RPO Code KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 531 Seat Heater Control Module: Diagrams Seat Cushion Ventilation Heat and Cool Module Seat Cushion Ventilation Heat And Cool Module - Driver (With RPO Code KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Climate Control Seat Module > Page 532 Seat Cushion Ventilation Heat & Cool Module - Passenger (With RPO Code KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Rear Seat Heater Control Module Replacement Seat Heater Control Module: Service and Repair Rear Seat Heater Control Module Replacement REAR SEAT HEATER CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Rear Seat Heater Control Module Replacement > Page 535 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Except Cadillac) MODULE REPLACEMENT - SEAT CLIMATE CONTROL - FRONT SEAT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Rear Seat Heater Control Module Replacement > Page 536 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Above The Headliner Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Closer Module > Component Information > Technical Service Bulletins > Body - Info on Liftgate Actuator Motor Change Trunk / Liftgate Closer Module: Technical Service Bulletins Body - Info on Liftgate Actuator Motor Change INFORMATION Bulletin No.: 09-08-66-007A Date: April 25, 2011 Subject: Information on Liftgate Close Actuator Motor Change Models: 2008-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, SRX 2007-2009 Chevrolet Suburban, Tahoe 2007-2009 GMC Acadia, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK All Equipped with Power Lift Gate RPO E61 or TB5 Supercede: This bulletin is being revised to change the build date for the Cadillac SRX. Please discard Corporate Bulletin Number 09-08-66-007 (Section 08 - Body and Accessories). 2009 models built after the following dates have changed the Liftgate Close Actuator Motor from a low frequency motor to a high frequency motor. The two units are not interchangeable. Important DO NOT use P/N 25889602 (low frequency motor) for vehicles built after the dates shown above. The running change from the low frequency Liftgate Close Actuator Motor to the high frequency Liftgate Close Actuator Motor can be identified by the following physical changes: The high frequency motor connector clutch circuits are on pins 13 and 14 (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Closer Module > Component Information > Technical Service Bulletins > Body - Info on Liftgate Actuator Motor Change > Page 544 The low frequency motor connector clutch circuits are on pins 3 and 4 (1). The high frequency motor utilizes a black tie wrap (1). The low frequency motor utilizes a white tie wrap (1). Parts Information Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations Trunk / Liftgate Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-05-25-004A > Aug > 07 > TCS/ABS - Rear Wheel Speed Sensor Data Reversed Electronic Brake Control Module: Customer Interest TCS/ABS - Rear Wheel Speed Sensor Data Reversed Bulletin No.: 06-05-25-004A Date: August 06, 2007 INFORMATION Subject: Information on Reprogramming EBCM if Tech 2(R) Data for Rear Wheel Speed Sensors is Reversed Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Built Prior to May 1, 2006 And Less Than 8600 lb GVW Supercede: This bulletin is being revised to include a "built prior to" date and remove the Silverado and Sierra models. Please discard Corporate Bulletin Number 06-05-25-004 (Section 05 - Brakes). When viewing rear wheel speed sensor information via a Tech 2(R), you may notice that the rear wheel speed data is reversed. The Tech 2(R) will show the left wheel speed data as the right on the Tech 2(R) screen and the right wheel speed data as the left. This is the result of the Electronic Brake Traction Control Module (EBCM) sending out the signal to the Tech 2(R) with the data swapped. If this condition is present, DO NOT replace the EBCM. To resolve this concern, reprogram the EBCM with updated calibrations. This new service calibration was released with TIS satellite data update version 5.0. Select EBCM in the TIS2000 supported controller list as the module. As always, make sure that your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-05-25-004A > Aug > 07 > TCS/ABS - Rear Wheel Speed Sensor Data Reversed Electronic Brake Control Module: All Technical Service Bulletins TCS/ABS - Rear Wheel Speed Sensor Data Reversed Bulletin No.: 06-05-25-004A Date: August 06, 2007 INFORMATION Subject: Information on Reprogramming EBCM if Tech 2(R) Data for Rear Wheel Speed Sensors is Reversed Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Built Prior to May 1, 2006 And Less Than 8600 lb GVW Supercede: This bulletin is being revised to include a "built prior to" date and remove the Silverado and Sierra models. Please discard Corporate Bulletin Number 06-05-25-004 (Section 05 - Brakes). When viewing rear wheel speed sensor information via a Tech 2(R), you may notice that the rear wheel speed data is reversed. The Tech 2(R) will show the left wheel speed data as the right on the Tech 2(R) screen and the right wheel speed data as the left. This is the result of the Electronic Brake Traction Control Module (EBCM) sending out the signal to the Tech 2(R) with the data swapped. If this condition is present, DO NOT replace the EBCM. To resolve this concern, reprogram the EBCM with updated calibrations. This new service calibration was released with TIS satellite data update version 5.0. Select EBCM in the TIS2000 supported controller list as the module. As always, make sure that your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 08-08-42-003A > Aug > 09 > Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: All Technical Service Bulletins Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 572 Electronic Brake Control Module: Locations Hydraulic Brake Component Views 1 - Windshield Wiper Motor 2 - Power Brake Booster 3 - Windshield Washer Solvent Heater 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) 7 - Brake Booster Vacuum Sensor 8 - Brake Fluid Level Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 573 Electronic Brake Control Module: Diagrams Antilock Brake System Connector End Views Electronic Brake Control Module (EBCM) (JL4 Under 8600 GVW) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 574 Electronic Brake Control Module (EBCM) (JL4 Under 8600 GVW) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 575 Electronic Brake Control Module (EBCM) (JH6 Over 8600 GVW) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (W/JL4) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (W/JL4) Electronic Brake Control Module Replacement (W/JL4) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove all dirt and debris from the electronic brake control module (EBCM) and the brake pressure modulator valve (BPMV) before loosening or removing any of the components. Important: DO NOT reuse the EBCM to BPMV screws. Install NEW screws. 3. Using denatured alcohol, clean the EBCM (2) and the BPMV (3). 4. Disconnect the EBCM electrical connector. 5. Remove and discard the EBCM to BPMV screws (1). 6. Carefully pull the EBCM (2) from the BPMV (3). 7. Remove the EBCM to BPMV gasket. Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (W/JL4) > Page 578 1. Position the gasket to the BPMV (3). 2. Position the EBCM (2) to the BPMV (3). Important: Make sure the EBCM is properly aligned to the BPMV, including the brake pressure switch. Do not force the components together. 3. Push the EBCM squarely onto the BPMV. Notice: Refer to Fastener Notice. 4. Install 4 new EBCM to BPMV screws (1). Tighten the screws in a X pattern to 3 N.m (27 lb in). 5. Connect the EBCM electrical connector. 6. If installing a replacement EBCM, program the replacement EBCM. Refer to Control Module References. 7. Bleed the BPMV. Refer to Antilock Brake System Automated Bleed Procedure (W/JL4) Antilock Brake System Automated Bleed Procedure (W/O JL4). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (W/JL4) > Page 579 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (W/O JL4) Electronic Brake Control Module Replacement (W/O JL4) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove all dirt and debris from the electronic brake control module (EBCM) and the brake pressure modulator valve (BPMV) before loosening or removing any of the components. Important: DO NOT reuse the EBCM to BPMV screws. Install NEW screws. 3. Using denatured alcohol, clean the EBCM (2) and the BPMV (3). 4. Disconnect the EBCM electrical connector. 5. Remove and discard the EBCM to BPMV screws (1). 6. Carefully pull the EBCM (2) from the BPMV (3). Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (W/JL4) > Page 580 1. Position the EBCM (2) to the BPMV (3). Notice: Refer to Fastener Notice. 2. Install 4 new EBCM to BPMV screws (1). Tighten the screws in an X pattern to 3 N.m (27 lb in). 3. Connect the EBCM electrical connector. 4. If installing a replacement EBCM, program the replacement EBCM. Refer to Control Module References. 5. Bleed the BPMV. Refer to Antilock Brake System Automated Bleed Procedure (W/JL4) Antilock Brake System Automated Bleed Procedure (W/O JL4). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 585 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 586 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 587 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 588 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 589 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 590 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 596 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 597 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 598 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 599 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 600 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 601 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 602 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 603 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 604 Radiator Cooling Fan Control Module: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 605 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 606 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 607 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 608 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 609 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 610 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 611 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 612 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 613 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 614 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 615 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 616 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 617 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 618 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 619 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 620 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 621 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 622 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 623 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 624 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 625 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 626 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 627 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 628 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 629 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 630 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 631 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 632 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 633 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 634 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 635 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 636 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 637 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 638 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 639 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 640 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 641 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 642 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 643 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 644 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 645 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 646 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 647 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 648 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 649 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 650 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 651 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 652 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 653 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 654 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 655 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 656 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 657 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 658 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 659 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 660 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 661 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 662 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 663 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 664 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 665 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 666 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 667 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 668 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 669 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 670 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 671 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 672 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 673 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 674 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 675 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 676 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 677 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 678 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 679 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 680 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 681 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 682 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 683 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 684 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 685 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 686 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module Relay > Component Information > Locations Radiator Cooling Fan Control Module Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 695 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 701 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 702 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Radiator Cooling Fan Motor Relay: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 704 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 705 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 708 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 709 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 710 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 711 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 713 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 714 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 716 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 717 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 718 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 719 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 720 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 722 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 723 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 724 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 725 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 726 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 727 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 728 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 729 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 730 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 731 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 732 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 733 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 734 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 735 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 736 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 737 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 739 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 740 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 741 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 742 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 743 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 744 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 745 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 746 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 747 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 748 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 749 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 750 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 751 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 752 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 753 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 754 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 755 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 756 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 757 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 758 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 759 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 760 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 761 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 762 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 763 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 764 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 765 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 766 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 767 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 768 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 769 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 770 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 771 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 772 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 773 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 774 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 775 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 776 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 777 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 778 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 779 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 780 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 781 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 782 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 783 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 784 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 785 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming Control Module HVAC: Recalls Campaign - HVAC Module Reprogramming Bulletin No.: 06024B Date: April 25, 2006 PRODUCT ENHANCEMENT Subject: 06024B - Product Enhancement for Inventory and Customer Vehicles - HVAC Module Reprogram - Expires with Base Warranty Models: 2007 Cadillac Escalade, Escalade ESV 2007 Chevrolet Suburban, Tahoe 2007 GMC Yukon, Yukon XL Supercede: THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED. PLEASE REVIEW THE NEW PROCEDURE IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 06024A, ISSUED MARCH 2006. THIS PRODUCT ENHANCEMENT INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE, AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to reprogram the HVAC module on certain 2007 Cadillac Escalade and Escalade ESV; Chevrolet Suburban and Tahoe; and GMC Yukon and Yukon XL vehicles. On rare occasions, when the vehicle is started at or below 32°F (0°C), the HVAC controls and display may become inoperative. This reprogramming should be completed as soon as possible on involved vehicles currently in dealership/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (GM US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming > Page 798 VIN breakpoints shown. should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Tech 2(R) Remote Programming Method for HVAC Module Note: Before reprogramming, please check the battery condition to prevent a reprogram error of the driver's seat module due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery such as automatic headlamps, daytime running lamps, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Program the HVAC Module to the latest calibration part number. Be sure to use the Remote Tech 2(R) programming method using both the Tech 2(R) with CANDi module and the TIS terminal. Important: Use data version 3.5 or later, broadcast to dealers, and available on TIS2WEB, March 19, 2006 (US), March 22, 2006 (Canada); and on TIS CD-ROM version 4.0/ 2006 which was mailed to dealers beginning April 18, 2006. To complete this service procedure, the Tech 2(R) must also be updated to release 26.002 or greater. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. HVAC Module Programming 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select HVAC Control Module from Supported Controllers window. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming > Page 799 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view the Summary screen. 15. Verify that the current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information For vehicles repaired under this product enhancement, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 08-01-39-009B > Sep > 10 > A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: Customer Interest A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 08-01-39-009B > Sep > 10 > A/C - Defaults To Full Hot/Full Cold/DTC's Set > Page 805 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-39-008 > Sep > 06 > A/C - Set temperature Doesn't Match Actual Temperature Control Module HVAC: Customer Interest A/C - Set temperature Doesn't Match Actual Temperature Bulletin No.: 06-01-39-008 Date: September 07, 2006 TECHNICAL Subject: Automatic HVAC System Set Temperature Does Not Provide Comfort (Update HVAC Control Module Software) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) Condition Some customers may comment that they have to adjust the Heating, Ventilation and Air Conditioning (HVAC) system set temperature lower to get the system to blow cool air. For example: If the customer wants to keep the in vehicle temperature at 22°C (72°F), they may have to reset the HVAC control head temperature setting to 18°C (65°F) or lower to achieve the desired 22°C (72°F). Cause This condition may be caused by an HVAC control module software anomaly. Correction Technicians are to reprogram the HVAC control module with new service calibrations contained in TIS version 5.0 or later, which has already been released. Refer to the HVAC Control Module Programming and Setup procedure in SI for more information. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-39-008 > Sep > 06 > A/C - Set temperature Doesn't Match Actual Temperature > Page 810 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 08-01-39-009B > Sep > 10 > A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 08-01-39-009B > Sep > 10 > A/C - Defaults To Full Hot/Full Cold/DTC's Set > Page 816 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 07-01-38-006 > Aug > 07 > A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 07-01-38-006 > Aug > 07 > A/C - Control Module A/C Indicator Blinking > Page 821 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-39-014 > Dec > 06 > A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-39-008 > Sep > 06 > A/C - Set temperature Doesn't Match Actual Temperature Control Module HVAC: All Technical Service Bulletins A/C - Set temperature Doesn't Match Actual Temperature Bulletin No.: 06-01-39-008 Date: September 07, 2006 TECHNICAL Subject: Automatic HVAC System Set Temperature Does Not Provide Comfort (Update HVAC Control Module Software) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) Condition Some customers may comment that they have to adjust the Heating, Ventilation and Air Conditioning (HVAC) system set temperature lower to get the system to blow cool air. For example: If the customer wants to keep the in vehicle temperature at 22°C (72°F), they may have to reset the HVAC control head temperature setting to 18°C (65°F) or lower to achieve the desired 22°C (72°F). Cause This condition may be caused by an HVAC control module software anomaly. Correction Technicians are to reprogram the HVAC control module with new service calibrations contained in TIS version 5.0 or later, which has already been released. Refer to the HVAC Control Module Programming and Setup procedure in SI for more information. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-39-008 > Sep > 06 > A/C - Set temperature Doesn't Match Actual Temperature > Page 830 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Module Reprogramming Bulletin No.: 06024B Date: April 25, 2006 PRODUCT ENHANCEMENT Subject: 06024B - Product Enhancement for Inventory and Customer Vehicles - HVAC Module Reprogram - Expires with Base Warranty Models: 2007 Cadillac Escalade, Escalade ESV 2007 Chevrolet Suburban, Tahoe 2007 GMC Yukon, Yukon XL Supercede: THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED. PLEASE REVIEW THE NEW PROCEDURE IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 06024A, ISSUED MARCH 2006. THIS PRODUCT ENHANCEMENT INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE, AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to reprogram the HVAC module on certain 2007 Cadillac Escalade and Escalade ESV; Chevrolet Suburban and Tahoe; and GMC Yukon and Yukon XL vehicles. On rare occasions, when the vehicle is started at or below 32°F (0°C), the HVAC controls and display may become inoperative. This reprogramming should be completed as soon as possible on involved vehicles currently in dealership/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (GM US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming > Page 835 VIN breakpoints shown. should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Tech 2(R) Remote Programming Method for HVAC Module Note: Before reprogramming, please check the battery condition to prevent a reprogram error of the driver's seat module due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery such as automatic headlamps, daytime running lamps, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Program the HVAC Module to the latest calibration part number. Be sure to use the Remote Tech 2(R) programming method using both the Tech 2(R) with CANDi module and the TIS terminal. Important: Use data version 3.5 or later, broadcast to dealers, and available on TIS2WEB, March 19, 2006 (US), March 22, 2006 (Canada); and on TIS CD-ROM version 4.0/ 2006 which was mailed to dealers beginning April 18, 2006. To complete this service procedure, the Tech 2(R) must also be updated to release 26.002 or greater. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. HVAC Module Programming 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select HVAC Control Module from Supported Controllers window. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming > Page 836 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view the Summary screen. 15. Verify that the current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information For vehicles repaired under this product enhancement, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 08-01-39-009B > Sep > 10 > A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 08-01-39-009B > Sep > 10 > A/C - Defaults To Full Hot/Full Cold/DTC's Set > Page 842 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 07-01-38-006 > Aug > 07 > A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 07-01-38-006 > Aug > 07 > A/C - Control Module A/C Indicator Blinking > Page 847 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-39-014 > Dec > 06 > A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-39-008 > Sep > 06 > A/C - Set temperature Doesn't Match Actual Temperature Control Module HVAC: All Technical Service Bulletins A/C - Set temperature Doesn't Match Actual Temperature Bulletin No.: 06-01-39-008 Date: September 07, 2006 TECHNICAL Subject: Automatic HVAC System Set Temperature Does Not Provide Comfort (Update HVAC Control Module Software) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) Condition Some customers may comment that they have to adjust the Heating, Ventilation and Air Conditioning (HVAC) system set temperature lower to get the system to blow cool air. For example: If the customer wants to keep the in vehicle temperature at 22°C (72°F), they may have to reset the HVAC control head temperature setting to 18°C (65°F) or lower to achieve the desired 22°C (72°F). Cause This condition may be caused by an HVAC control module software anomaly. Correction Technicians are to reprogram the HVAC control module with new service calibrations contained in TIS version 5.0 or later, which has already been released. Refer to the HVAC Control Module Programming and Setup procedure in SI for more information. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-39-008 > Sep > 06 > A/C - Set temperature Doesn't Match Actual Temperature > Page 856 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 07-01-38-006 > Aug > 07 > A/C - Control Module A/C Indicator Blinking > Page 862 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Module Reprogramming Bulletin No.: 06024B Date: April 25, 2006 PRODUCT ENHANCEMENT Subject: 06024B - Product Enhancement for Inventory and Customer Vehicles - HVAC Module Reprogram - Expires with Base Warranty Models: 2007 Cadillac Escalade, Escalade ESV 2007 Chevrolet Suburban, Tahoe 2007 GMC Yukon, Yukon XL Supercede: THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED. PLEASE REVIEW THE NEW PROCEDURE IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 06024A, ISSUED MARCH 2006. THIS PRODUCT ENHANCEMENT INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE, AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to reprogram the HVAC module on certain 2007 Cadillac Escalade and Escalade ESV; Chevrolet Suburban and Tahoe; and GMC Yukon and Yukon XL vehicles. On rare occasions, when the vehicle is started at or below 32°F (0°C), the HVAC controls and display may become inoperative. This reprogramming should be completed as soon as possible on involved vehicles currently in dealership/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (GM US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming > Page 871 VIN breakpoints shown. should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Tech 2(R) Remote Programming Method for HVAC Module Note: Before reprogramming, please check the battery condition to prevent a reprogram error of the driver's seat module due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery such as automatic headlamps, daytime running lamps, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Program the HVAC Module to the latest calibration part number. Be sure to use the Remote Tech 2(R) programming method using both the Tech 2(R) with CANDi module and the TIS terminal. Important: Use data version 3.5 or later, broadcast to dealers, and available on TIS2WEB, March 19, 2006 (US), March 22, 2006 (Canada); and on TIS CD-ROM version 4.0/ 2006 which was mailed to dealers beginning April 18, 2006. To complete this service procedure, the Tech 2(R) must also be updated to release 26.002 or greater. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. HVAC Module Programming 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select HVAC Control Module from Supported Controllers window. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06024B > Apr > 06 > Campaign - HVAC Module Reprogramming > Page 872 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view the Summary screen. 15. Verify that the current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information For vehicles repaired under this product enhancement, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC System - Automatic Control Module HVAC: Locations HVAC System - Automatic Front Of The I/P (Except RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC System - Automatic > Page 875 Front Of The I/P (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC System - Automatic > Page 876 Front HVAC Module Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC System - Automatic > Page 877 Middle Of The Headliner Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic Control Module HVAC: Diagrams HVAC System - Automatic Blower Motor Control Module C1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 880 Blower Motor Control Module C2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 881 Blower Motor Control Module - Auxiliary C1 (LWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 882 Blower Motor Control Module - Auxiliary C1 (SWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 883 Blower Motor Control Module - Auxiliary C2 (LWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 884 Blower Motor Control Module - Auxiliary C2 (SWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 885 Control Module HVAC: Diagrams HVAC System - Manual Blower Motor Control Module - Auxiliary C1 (LWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 886 Blower Motor Control Module - Auxiliary C1 (SWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 887 Blower Motor Control Module - Auxiliary C2 (LWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 888 Blower Motor Control Module - Auxiliary C2 (SWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 889 Blower Motor Control Module C1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 890 Blower Motor Control Module C2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 891 HVAC Control Module - Auxiliary (With RPO Code CJ3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 892 HVAC Control Module C1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 893 HVAC Control Module C2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 894 HVAC Control Module C3 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 895 HVAC Control Module C4 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Auxiliary Blower Control Module Replacement Control Module HVAC: Service and Repair Auxiliary Blower Control Module Replacement AUXILIARY BLOWER CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Auxiliary Blower Control Module Replacement > Page 898 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement BLOWER MOTOR CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: Customer Interest Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting > Page 908 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting > Page 909 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting > Page 910 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: All Technical Service Bulletins Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting > Page 916 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting > Page 917 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 07-08-49-029A > Jan > 08 > Instruments - Hard to See/Poor Backlighting > Page 918 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 923 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 924 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 925 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 926 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 927 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 934 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 935 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 936 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 937 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 938 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 942 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 943 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 944 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 945 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 946 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS) REMOVAL PROCEDURE 1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. 4. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 955 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) RELAY REPLACEMENT (WITHIN AN ELECTRICAL CENTER) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. 3. IMPORTANT: - Always note the orientation of the relay. - Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. Using the J 43244 (1) position the tool on opposing corners of the relay (2). 4. NOTE: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 966 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-06-03-013D > Sep > 09 > Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-06-03-013D > Sep > 09 > Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 > Page 971 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked Body Control Module: All Technical Service Bulletins Body - Power Lift Gate/Liftgate Remains Locked Bulletin No.: 06-08-47-002A Date: March 28, 2006 TECHNICAL Subject: Power Lift Gate/Liftgate Remains Locked (Reprogram BCM and Lift Gate Module [LGM] with Updated Software) Models: 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon with Power Lift Gate (RPO E61) Supercede: This bulletin is being revised to use Remote programming instead of Pass-Thru. Programming using the Remote method will prevent many, if not all, of the DTCs from setting in other modules. The labor time has been reduced to reflect this change. Please discard Corporate Bulletin Number 06-08-47-002 (Section 08 Body & Accessories). Condition Some customers may comment on any of the following conditions with the power liftgate: ^ If the vehicle is locked and then the unlock button is pressed on the transmitter once for the driver's door unlock, a second time for all doors, and then a third time for the lift gate, the lift gate will be locked even though the other doors are unlocked. ^ If the vehicle is already unlocked (all doors unlocked), and the unlock button is pressed on the transmitter once for the driver door unlock, the lift gate will be locked. Under these conditions, the lift gate cannot be opened in either manual or automatic mode using the exterior handle. ^ The overhead console switch does not work. Cause Engineering has determined that these conditions are caused by software anomalies found in the BCM and in the Lift Gate Module (LGM) software. Correction DO NOT REPLACE THE LIFT GATE MODULE OR BCM. Use the following procedure to reprogram the BCM with software P/N 15901392, and PLGM with software P/N 15912911 (released with TIS broadcast March 5, 2006 or later) to correct this condition. 1. If the customer brought their vehicle in for any other concerns, be sure to check all modules and note any DTCs that have been set. These DTCs may be related to another customer concern listed on the repair order. 2. Using the TIS Remote programming method, reprogram the Lift Gate Module. 3. After programming is complete for the lift gate module, turn off the ignition for 30 seconds. 4. Use the Tech 2(R) to perform the Lift Gate Calibration procedure, which resets the limits for the open/close function of the lift gate. Lift Gate Calibration Procedure Tech 2(R) Path: 4.1. Body 4.2. LGM (Lift Gate Module) 4.3. Special Functions 4.4. Lift Gate Open/Close Test Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked > Page 976 5. Using TIS Remote programming method, reprogram the BCM. 6. After programming is complete for the BCM, turn off the ignition for 30 seconds. 7. Use the Tech 2(R) to perform the BCM Module Setup. ^ Select "Diagnostics". ^ Select Model Year. ^ Select Vehicle Type. ^ Select Make. ^ Select Product Line. ^ Select Product Series. ^ F1: Body ^ Select HVAC System. ^ Select "Body Control Module". ^ F5: Module Set-up ^ F0: Set-up SDM Primary Key in BCM Important: The labor operation listed in this bulletin includes the necessary time to check and clear all DTCs. 8. After the BCM is complete, check and clear all DTCs using the following Tech 2(R) path: ^ Select Diagnostic. ^ Select Model Year. ^ Select Vehicle Type. ^ Select Product Make. ^ Select Product Line. ^ Select Product Series. ^ F3: Vehicle Control Systems ^ Select Engine Type. ^ F0: Vehicle DTC Information ^ F0: DTC Display ^ Check and clear all DTCs from modules. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked > Page 977 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 982 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 983 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 984 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Malfunctions Bulletin No.: 07-08-49-001 Date: January 18, 2007 TECHNICAL Subject: Various Electrical Concerns - Hood Open Message Displayed, Door Locks Inoperative, Brake Warning Lamp On (Replace BCM and Install Connector Service Kit) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on various electrical concerns. Some of the conditions that may be present are: Hood Open Message Displayed in DIC Door Locks Inoperative Brake Warning Lamp On Cause These conditions may be due to the engine cooling fans inducing a voltage spike that damages the BCM internally. Correction Replace the BCM and install connector service kit, P/N 25777448, at the BCM to prevent conditions from reoccurring. Use the service procedure listed below. Remove the push pin retainers and the left side closeout/insulator panel. Remove the retaining screws and the steering column opening filler panel. Remove the retaining bolts and the driver knee bolster. Disconnect the BCM connectors. Remove the BCM from its mounting bracket. Install the new BCM to its mounting bracket. Remove the BCM wiring harness clip to allow for slack. Install diode # 1. Locate BCM connector C4 (black). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions > Page 989 Open the harness by removing the tape. Locate the pink/black wire, circuit 109, connector pin 17. Cut the wire approximately 25 mm (1 in) up from the connector end. Splice in the diode using the supplied duraseal splice sleeves. Red lead wire (+) goes toward BCM. Shrink the insulation around the splice using a heat touch. Tape the diode to the harness using electrical tape. Install diode # 2. Locate BCM connector C5 (brown). Open the harness by removing the tape. Locate the purple wire, circuit 5531, connector pin 15. Cut the wire approximately 25 mm (1 in) up from the connector end. Splice in the diode using the supplied duraseal splice sleeves. Red lead wire (+) goes toward BCM. Shrink the insulation around the splice using a heat touch. Tape the diode to the harness using electrical tape. Install the BCM wiring harness clip. Connect the BCM connectors. Install the driver knee bolster and retaining bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). Install the steering column opening filler panel and retaining screws. Tighten Tighten the bolts to 2 N.m (18 lb in). Install the left side closeout/insulator panel and push pin retainers. Program the BCM. Refer to the Body Control Module (BCM) Programming/RPO Configuration in SI. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions > Page 990 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-06-03-009 > Oct > 06 > Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain Body Control Module: Recalls Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 1000 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 1001 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 1002 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-03-013D > Sep > 09 > Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: Customer Interest Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-03-013D > Sep > 09 > Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 > Page 1008 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked Body Control Module: Customer Interest Body - Power Lift Gate/Liftgate Remains Locked Bulletin No.: 06-08-47-002A Date: March 28, 2006 TECHNICAL Subject: Power Lift Gate/Liftgate Remains Locked (Reprogram BCM and Lift Gate Module [LGM] with Updated Software) Models: 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon with Power Lift Gate (RPO E61) Supercede: This bulletin is being revised to use Remote programming instead of Pass-Thru. Programming using the Remote method will prevent many, if not all, of the DTCs from setting in other modules. The labor time has been reduced to reflect this change. Please discard Corporate Bulletin Number 06-08-47-002 (Section 08 Body & Accessories). Condition Some customers may comment on any of the following conditions with the power liftgate: ^ If the vehicle is locked and then the unlock button is pressed on the transmitter once for the driver's door unlock, a second time for all doors, and then a third time for the lift gate, the lift gate will be locked even though the other doors are unlocked. ^ If the vehicle is already unlocked (all doors unlocked), and the unlock button is pressed on the transmitter once for the driver door unlock, the lift gate will be locked. Under these conditions, the lift gate cannot be opened in either manual or automatic mode using the exterior handle. ^ The overhead console switch does not work. Cause Engineering has determined that these conditions are caused by software anomalies found in the BCM and in the Lift Gate Module (LGM) software. Correction DO NOT REPLACE THE LIFT GATE MODULE OR BCM. Use the following procedure to reprogram the BCM with software P/N 15901392, and PLGM with software P/N 15912911 (released with TIS broadcast March 5, 2006 or later) to correct this condition. 1. If the customer brought their vehicle in for any other concerns, be sure to check all modules and note any DTCs that have been set. These DTCs may be related to another customer concern listed on the repair order. 2. Using the TIS Remote programming method, reprogram the Lift Gate Module. 3. After programming is complete for the lift gate module, turn off the ignition for 30 seconds. 4. Use the Tech 2(R) to perform the Lift Gate Calibration procedure, which resets the limits for the open/close function of the lift gate. Lift Gate Calibration Procedure Tech 2(R) Path: 4.1. Body 4.2. LGM (Lift Gate Module) 4.3. Special Functions 4.4. Lift Gate Open/Close Test Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked > Page 1013 5. Using TIS Remote programming method, reprogram the BCM. 6. After programming is complete for the BCM, turn off the ignition for 30 seconds. 7. Use the Tech 2(R) to perform the BCM Module Setup. ^ Select "Diagnostics". ^ Select Model Year. ^ Select Vehicle Type. ^ Select Make. ^ Select Product Line. ^ Select Product Series. ^ F1: Body ^ Select HVAC System. ^ Select "Body Control Module". ^ F5: Module Set-up ^ F0: Set-up SDM Primary Key in BCM Important: The labor operation listed in this bulletin includes the necessary time to check and clear all DTCs. 8. After the BCM is complete, check and clear all DTCs using the following Tech 2(R) path: ^ Select Diagnostic. ^ Select Model Year. ^ Select Vehicle Type. ^ Select Product Make. ^ Select Product Line. ^ Select Product Series. ^ F3: Vehicle Control Systems ^ Select Engine Type. ^ F0: Vehicle DTC Information ^ F0: DTC Display ^ Check and clear all DTCs from modules. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked > Page 1014 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions Body Control Module: Customer Interest Electrical - Various Electrical Malfunctions Bulletin No.: 07-08-49-001 Date: January 18, 2007 TECHNICAL Subject: Various Electrical Concerns - Hood Open Message Displayed, Door Locks Inoperative, Brake Warning Lamp On (Replace BCM and Install Connector Service Kit) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on various electrical concerns. Some of the conditions that may be present are: Hood Open Message Displayed in DIC Door Locks Inoperative Brake Warning Lamp On Cause These conditions may be due to the engine cooling fans inducing a voltage spike that damages the BCM internally. Correction Replace the BCM and install connector service kit, P/N 25777448, at the BCM to prevent conditions from reoccurring. Use the service procedure listed below. Remove the push pin retainers and the left side closeout/insulator panel. Remove the retaining screws and the steering column opening filler panel. Remove the retaining bolts and the driver knee bolster. Disconnect the BCM connectors. Remove the BCM from its mounting bracket. Install the new BCM to its mounting bracket. Remove the BCM wiring harness clip to allow for slack. Install diode # 1. Locate BCM connector C4 (black). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions > Page 1019 Open the harness by removing the tape. Locate the pink/black wire, circuit 109, connector pin 17. Cut the wire approximately 25 mm (1 in) up from the connector end. Splice in the diode using the supplied duraseal splice sleeves. Red lead wire (+) goes toward BCM. Shrink the insulation around the splice using a heat touch. Tape the diode to the harness using electrical tape. Install diode # 2. Locate BCM connector C5 (brown). Open the harness by removing the tape. Locate the purple wire, circuit 5531, connector pin 15. Cut the wire approximately 25 mm (1 in) up from the connector end. Splice in the diode using the supplied duraseal splice sleeves. Red lead wire (+) goes toward BCM. Shrink the insulation around the splice using a heat touch. Tape the diode to the harness using electrical tape. Install the BCM wiring harness clip. Connect the BCM connectors. Install the driver knee bolster and retaining bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). Install the steering column opening filler panel and retaining screws. Tighten Tighten the bolts to 2 N.m (18 lb in). Install the left side closeout/insulator panel and push pin retainers. Program the BCM. Refer to the Body Control Module (BCM) Programming/RPO Configuration in SI. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions > Page 1020 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-03-009 > Oct > 06 > Electrical - Battery Goes Dead Overnight Body Control Module: Customer Interest Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 1030 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-06-03-013D > Sep > 09 > Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-06-03-013D > Sep > 09 > Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 > Page 1035 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked Body Control Module: All Technical Service Bulletins Body - Power Lift Gate/Liftgate Remains Locked Bulletin No.: 06-08-47-002A Date: March 28, 2006 TECHNICAL Subject: Power Lift Gate/Liftgate Remains Locked (Reprogram BCM and Lift Gate Module [LGM] with Updated Software) Models: 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon with Power Lift Gate (RPO E61) Supercede: This bulletin is being revised to use Remote programming instead of Pass-Thru. Programming using the Remote method will prevent many, if not all, of the DTCs from setting in other modules. The labor time has been reduced to reflect this change. Please discard Corporate Bulletin Number 06-08-47-002 (Section 08 Body & Accessories). Condition Some customers may comment on any of the following conditions with the power liftgate: ^ If the vehicle is locked and then the unlock button is pressed on the transmitter once for the driver's door unlock, a second time for all doors, and then a third time for the lift gate, the lift gate will be locked even though the other doors are unlocked. ^ If the vehicle is already unlocked (all doors unlocked), and the unlock button is pressed on the transmitter once for the driver door unlock, the lift gate will be locked. Under these conditions, the lift gate cannot be opened in either manual or automatic mode using the exterior handle. ^ The overhead console switch does not work. Cause Engineering has determined that these conditions are caused by software anomalies found in the BCM and in the Lift Gate Module (LGM) software. Correction DO NOT REPLACE THE LIFT GATE MODULE OR BCM. Use the following procedure to reprogram the BCM with software P/N 15901392, and PLGM with software P/N 15912911 (released with TIS broadcast March 5, 2006 or later) to correct this condition. 1. If the customer brought their vehicle in for any other concerns, be sure to check all modules and note any DTCs that have been set. These DTCs may be related to another customer concern listed on the repair order. 2. Using the TIS Remote programming method, reprogram the Lift Gate Module. 3. After programming is complete for the lift gate module, turn off the ignition for 30 seconds. 4. Use the Tech 2(R) to perform the Lift Gate Calibration procedure, which resets the limits for the open/close function of the lift gate. Lift Gate Calibration Procedure Tech 2(R) Path: 4.1. Body 4.2. LGM (Lift Gate Module) 4.3. Special Functions 4.4. Lift Gate Open/Close Test Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked > Page 1040 5. Using TIS Remote programming method, reprogram the BCM. 6. After programming is complete for the BCM, turn off the ignition for 30 seconds. 7. Use the Tech 2(R) to perform the BCM Module Setup. ^ Select "Diagnostics". ^ Select Model Year. ^ Select Vehicle Type. ^ Select Make. ^ Select Product Line. ^ Select Product Series. ^ F1: Body ^ Select HVAC System. ^ Select "Body Control Module". ^ F5: Module Set-up ^ F0: Set-up SDM Primary Key in BCM Important: The labor operation listed in this bulletin includes the necessary time to check and clear all DTCs. 8. After the BCM is complete, check and clear all DTCs using the following Tech 2(R) path: ^ Select Diagnostic. ^ Select Model Year. ^ Select Vehicle Type. ^ Select Product Make. ^ Select Product Line. ^ Select Product Series. ^ F3: Vehicle Control Systems ^ Select Engine Type. ^ F0: Vehicle DTC Information ^ F0: DTC Display ^ Check and clear all DTCs from modules. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-08-47-002A > Mar > 07 > Body - Power Lift Gate/Liftgate Remains Locked > Page 1041 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Malfunctions Bulletin No.: 07-08-49-001 Date: January 18, 2007 TECHNICAL Subject: Various Electrical Concerns - Hood Open Message Displayed, Door Locks Inoperative, Brake Warning Lamp On (Replace BCM and Install Connector Service Kit) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Built Prior to the VIN Breakpoints shown. Condition Some customers may comment on various electrical concerns. Some of the conditions that may be present are: Hood Open Message Displayed in DIC Door Locks Inoperative Brake Warning Lamp On Cause These conditions may be due to the engine cooling fans inducing a voltage spike that damages the BCM internally. Correction Replace the BCM and install connector service kit, P/N 25777448, at the BCM to prevent conditions from reoccurring. Use the service procedure listed below. Remove the push pin retainers and the left side closeout/insulator panel. Remove the retaining screws and the steering column opening filler panel. Remove the retaining bolts and the driver knee bolster. Disconnect the BCM connectors. Remove the BCM from its mounting bracket. Install the new BCM to its mounting bracket. Remove the BCM wiring harness clip to allow for slack. Install diode # 1. Locate BCM connector C4 (black). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions > Page 1046 Open the harness by removing the tape. Locate the pink/black wire, circuit 109, connector pin 17. Cut the wire approximately 25 mm (1 in) up from the connector end. Splice in the diode using the supplied duraseal splice sleeves. Red lead wire (+) goes toward BCM. Shrink the insulation around the splice using a heat touch. Tape the diode to the harness using electrical tape. Install diode # 2. Locate BCM connector C5 (brown). Open the harness by removing the tape. Locate the purple wire, circuit 5531, connector pin 15. Cut the wire approximately 25 mm (1 in) up from the connector end. Splice in the diode using the supplied duraseal splice sleeves. Red lead wire (+) goes toward BCM. Shrink the insulation around the splice using a heat touch. Tape the diode to the harness using electrical tape. Install the BCM wiring harness clip. Connect the BCM connectors. Install the driver knee bolster and retaining bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). Install the steering column opening filler panel and retaining screws. Tighten Tighten the bolts to 2 N.m (18 lb in). Install the left side closeout/insulator panel and push pin retainers. Program the BCM. Refer to the Body Control Module (BCM) Programming/RPO Configuration in SI. Parts Information Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-49-001 > Jan > 07 > Electrical - Various Electrical Malfunctions > Page 1047 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-06-03-009 > Oct > 06 > Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 1057 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 1062 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 1063 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07033B > Feb > 07 > Campaign - BCM Reprogramming for Battery Drain > Page 1064 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) Auxiliary Body Control Module (XBCM) C1 (Export) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1067 Auxiliary Body Control Module (XBCM) C2 (Export) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1068 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module (BCM) C1 (Pin 1 To 19) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1069 Body Control Module (BCM) C1 (Pin 20 To 27) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1070 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module (BCM) C2 (Pin 1 To 16) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1071 Body Control Module (BCM) C2 (Pin 17 To 25) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1072 Body Control Module: Diagrams Auxiliary Body Control Module (XBCM) C1 (Export) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1073 Auxiliary Body Control Module (XBCM) C2 (Export) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1074 Body Control Module (BCM) C1 (Pin 1 To 19) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1075 Body Control Module (BCM) C1 (Pin 20 To 27) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1076 Body Control Module (BCM) C2 (Pin 1 To 16) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1077 Body Control Module (BCM) C2 (Pin 17 To 25) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1078 Body Control Module (BCM) C3 (Pin 1 To 12) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1079 Body Control Module (BCM) C3 (Pin 13 To 25) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1080 Body Control Module (BCM) C4 (Pin 1 To 11) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1081 Body Control Module (BCM) C4 (Pin 12 To 25) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1082 Body Control Module (BCM) C5 (Pin 1 To 9) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1083 Body Control Module (BCM) C5 (Pin 10 To 25) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1084 Body Control Module (BCM) C6 (Pin 1 To 23) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1085 Body Control Module (BCM) C6 (Pin 24 To 25) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Auxiliary Body Control Module (XBCM) C1 (Export) > Page 1086 Body Control Module (BCM) C7 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 1087 Body Control Module: Description and Operation BODY CONTROL SYSTEM DESCRIPTION AND OPERATION The body control system consists of the body control module (BCM), communications, and various input and outputs. Some inputs, outputs and messages require other modules to interact with the BCM. The BCM also has discrete input and output terminals to control the vehicle's body functions. The BCM is wired to the GMLAN high speed serial data buss and the GMLAN low speed serial data buss and acts as a gateway between them. If the BCM does not communicate the vehicle will not start due to the inability of the engine control module (ECM)/powertrain control module (PCM) and theft deterrent module (TDM) to communicate without the BCM providing the gateway function. Power Mode Master This vehicles body control module (BCM) functions as the power mode master (PMM). The ignition switch is a low current switch with multiple discrete ignition switch signals to the PMM for determination the power mode that will be sent over the serial data circuits to the other modules that need this information, and so the PMM will activate relays and other direct outputs of the PMM as needed. Refer to Power Mode Description and Operation for a complete description of power mode functions. Serial Data Gateway The body control module (BCM) in this vehicle functions as a gateway or translator. The purpose of the gateway is to translate serial data messages between the GMLAN high speed buss and the GMLAN low speed buss for communication between the various modules. The gateway will interact with each network according to that network's transmission protocol. One example of this necessary communication is the communication between the engine control module (ECM)/powertrain control module (PCM) which is high speed serial data and Theft Deterrent Module which is low speed serial data. If these modules can not exchange information, the vehicle will not start. Communication between the BCM and a scan tool can be on the high speed GMLAN network or low speed GMLAN network. If one network is lost, the BCM can still communicate with the scan tool. A lost communication DTC typically is set in modules other than the module with a communication failure. Body Control Module The various body control module (BCM) input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. Some BCM functions with the subsystems may be as a gateway only or as an enable for the system. The BCM related systems/subsystems include, but are not limited to the following: Antilock Brake System (ABS)-Refer to ABS Description and Operation (Under 8600 GVW ) ABS Description and Operation (Equal to or Over 8600 GVW). - Automatic Day-Night Mirror-Refer to Automatic Day-Night Mirror Description and Operation. - Cruise Control System-Refer to Cruise Control Description and Operation. - Electrical Power Management (EPM)-Refer to Electrical Power Management Description and Operation. - Exterior Lighting-Refer to Exterior Lighting Systems Description and Operation. - Horn System-Refer to Horns System Description and Operation. - HVAC-Refer to Air Delivery Description and Operation and Air Temperature Description and Operation. - Instrument Cluster Indicator Control-Refer to Instrument Cluster Description and Operation. - Interior Lighting-Refer to Interior Lighting Systems Description and Operation. - Power Door Lock System-Refer to Power Door Locks Description and Operation. - Rear Window Defogger System-Refer to Rear Window Defogger Description and Operation. - Redundant Steering Wheel Controls-Refer to Steering Wheel Controls Description and Operation. - Remote Function Actuation (RFA) Control-Refer to Keyless Entry System Description and Operation. - Retained Accessory Power (RAP)-Refer to Retained Accessory Power (RAP) Description and Operation. - Shift Lock Control System-Refer to Automatic Transmission Shift Lock Control Description and Operation. - Starting System-Refer to Starting System Description and Operation. - Supplemental Inflatable Restraint (SIR) System-Refer to SIR System Description and Operation. - Suspension System-Refer to Electronic Suspension Control Description and Operation. - Theft Deterrent-Refer to Content Theft Deterrent (CTD) Description and Operation. - Tire Pressure Monitor (TPM) System-Refer to Tire Pressure Monitor Description and Operation. - Wiper/Washer System Functions-Refer to Wiper/Washer System Description and Operation. Export Body Control Module The export body control system has an additional body control module located in the rear of the vehicle. This additional body control module is referred to as the XBCM. The XBCM has discrete input and output terminals to control additional vehicle body functions not supported by the primary body control module (BCM). The XBCM is wired to the GMLAN low speed serial data buss and the BCM and acts as a gateway between them. If the XBCM does not communicate, various rear end lighting such as rear fog lamps and trailer lighting will be impaired. The various input and output circuits are described in the corresponding functional areas indicated on the XBCM electrical schematics. Some XBCM functions with the subsystems may be as a gateway only or as an enable for the system. The XBCM related systems/subsystems include, but are not limited to the following: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 1088 - Exterior lighting-Refer to Exterior Lighting Systems Description and Operation. - Instrument cluster indicator control-Refer to Instrument Cluster Description and Operation. - Theft deterrent-Refer to Content Theft Deterrent (CTD) Description and Operation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement AUXILIARY BODY CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 1091 Body Control Module: Service and Repair Body Control Module Replacement BODY CONTROL MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 1100 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 1106 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 1111 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 1112 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 1113 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 1118 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 1119 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 1120 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-06-04-046 > Sep > 06 > Engine Controls - MIL ON/Misfire/Misfire DTC's Set > Page 1125 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 1131 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 1136 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 1137 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 1138 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 1143 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 1144 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 1145 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 1146 Left Side of The Engine Compartment Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Engine Control Module: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1210 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1211 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1216 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1218 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1219 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 Engine Control Module: Connector Views Engine Control Module (ECM) C1 (Pin 1 To 13) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 Engine Control Module (ECM) C1 (Pin 14 To 70) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 Engine Control Module (ECM) C1 (Pin 71 To 73) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 Engine Control Module (ECM) C2 (Pin 1 To 10) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 Engine Control Module (ECM) C2 (Pin 11 To 63) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 Engine Control Module (ECM) C2 (Pin 64 To 80) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1246 Engine Control Module: Service Precautions Powertrain Control Module and Electrostatic Discharge Notice Notice: Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1247 Engine Control Module: Description and Operation ENGINE CONTROL MODULE DESCRIPTION The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1248 Engine Control Module: Service and Repair ENGINE CONTROL MODULE REPLACEMENT Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. NOTE: - Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. - Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. - In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. - Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. - The replacement control module must be programmed. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1249 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1250 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Control Module References. See: Testing and Inspection/Programming and Relearning Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1254 Main Relay (Computer/Fuel System): Testing and Inspection POWER TRAIN RELAY DIAGNOSIS DIAGNOSTIC INSTRUCTIONS - Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. - Strategy Based Diagnosis for an overview of the diagnostic approach. - Diagnostic Procedure Instructions provide an overview of each diagnostic category. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Starting Point - Vehicle TYPICAL SCAN TOOL DATA EC Ignition Relay CIRCUIT/SYSTEM DESCRIPTION The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. DIAGNOSTIC AIDS This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test CIRCUIT/SYSTEM VERIFICATION 1. IMPORTANT: On the scan tool, the powertrain relay is referred to as the EC ignition relay. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. - If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. - If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. - If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. - If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. - If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. - If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1255 - If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. - If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: - Terminal 30 and 86 - Terminal 30 and 87 - Terminal 30 and 85 - Terminal 85 and 87 - If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center) - Underhood Electrical Center or Junction Block Replacement - Control Module References for ECM replacement, setup, and programming. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-03-011B > Feb > 07 > Fuel System - Hum/Buzz From Vehicle Rear/Battery Dies Fuel Pump Relay: Customer Interest Fuel System - Hum/Buzz From Vehicle Rear/Battery Dies Bulletin No.: 06-06-03-011B Date: February 16, 2007 TECHNICAL Subject: Hum or Buzz Noise From Rear of Vehicle and/or Possible Dead Battery (Check Fuel Pump Relay and Replace, if Necessary) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with 5.3L or 6.2L Gas Engine (VINs J, M, 3, 0, 8 - RPOs LY5, LH6, LC9, LMG, L92) and Built Prior to October 13, 2006 Attention: Use GMVIS to determine the vehicle build date. Supercede: This bulletin is being revised to add the production build date to the models. Please discard Corporate Bulletin Number 06-06-03-011A (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a buzz or hum type noise coming from the rear of the vehicle after the vehicle has been turned off. The customer may comment that the noise is intermittent and may also be associated with a low or dead battery, causing a no start condition. Cause The contacts in the fuel pump relay may be staying engaged after the vehicle is shut off, causing the battery drain. Correction Check for the fuel pump relay staying engaged (sticking). If you find that the relay is sticking, replace the relay and retest the system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-03-011B > Feb > 07 > Fuel System - Hum/Buzz From Vehicle Rear/Battery Dies > Page 1265 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-03-011B > Feb > 07 > Fuel System - Hum/Buzz From Vehicle Rear/Battery Dies Fuel Pump Relay: All Technical Service Bulletins Fuel System - Hum/Buzz From Vehicle Rear/Battery Dies Bulletin No.: 06-06-03-011B Date: February 16, 2007 TECHNICAL Subject: Hum or Buzz Noise From Rear of Vehicle and/or Possible Dead Battery (Check Fuel Pump Relay and Replace, if Necessary) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with 5.3L or 6.2L Gas Engine (VINs J, M, 3, 0, 8 - RPOs LY5, LH6, LC9, LMG, L92) and Built Prior to October 13, 2006 Attention: Use GMVIS to determine the vehicle build date. Supercede: This bulletin is being revised to add the production build date to the models. Please discard Corporate Bulletin Number 06-06-03-011A (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a buzz or hum type noise coming from the rear of the vehicle after the vehicle has been turned off. The customer may comment that the noise is intermittent and may also be associated with a low or dead battery, causing a no start condition. Cause The contacts in the fuel pump relay may be staying engaged after the vehicle is shut off, causing the battery drain. Correction Check for the fuel pump relay staying engaged (sticking). If you find that the relay is sticking, replace the relay and retest the system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-03-011B > Feb > 07 > Fuel System - Hum/Buzz From Vehicle Rear/Battery Dies > Page 1271 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Relay: > 08-08-42-004 > Aug > 08 > Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Relay: > 08-08-42-004 > Aug > 08 > Lighting - Dome/Reading Lamps Inoperative > Page 1277 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Relay: > 08-08-42-004 > Aug > 08 > Lighting - Dome/Reading Lamps Inoperative > Page 1283 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 1284 Fuel Pump Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1287 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1288 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1289 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1290 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1291 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1292 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1293 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1294 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1295 Fuel Pump Relay: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1296 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1297 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1298 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1299 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1300 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1301 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1302 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1303 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1304 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1305 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1306 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1307 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1308 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1309 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1310 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1311 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1312 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1313 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1314 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1315 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1316 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1317 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1318 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1319 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1320 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1321 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1322 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1323 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1324 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1325 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1326 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1327 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1328 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1329 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1330 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1331 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1332 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1333 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1334 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1357 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1358 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1359 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1360 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1361 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1368 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 Fuel Pump Relay - Secondary (Except RPO Code NQZ) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1382 Main Relay (Computer/Fuel System): Testing and Inspection POWER TRAIN RELAY DIAGNOSIS DIAGNOSTIC INSTRUCTIONS - Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. - Strategy Based Diagnosis for an overview of the diagnostic approach. - Diagnostic Procedure Instructions provide an overview of each diagnostic category. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Starting Point - Vehicle TYPICAL SCAN TOOL DATA EC Ignition Relay CIRCUIT/SYSTEM DESCRIPTION The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. DIAGNOSTIC AIDS This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test CIRCUIT/SYSTEM VERIFICATION 1. IMPORTANT: On the scan tool, the powertrain relay is referred to as the EC ignition relay. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. - If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. - If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. - If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. - If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. - If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. - If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1383 - If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. - If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: - Terminal 30 and 86 - Terminal 30 and 87 - Terminal 30 and 85 - Terminal 85 and 87 - If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center) - Underhood Electrical Center or Junction Block Replacement - Control Module References for ECM replacement, setup, and programming. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 1393 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 1394 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start Air Bag Control Module: Customer Interest Restraints - Pass. Seat Belt Lamp ON/After Remote Start Bulletin No.: 06-09-40-002 Date: July 13, 2006 TECHNICAL Subject: Passenger Safety Belt Reminder Light Remains On After Remote Start (Perform Appropriate Corrective Action Below)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Remote Start (RPO AP3) Condition Some customers may comment that the passenger safety belt reminder light remains on with the passenger seatbelt buckled after a remote start. Cause This condition may be caused by a software anomaly within the SDM. Correction Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start > Page 1399 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start > Page 1400 It is important that you first identify the calibration number that is in the SDM. This can be done using the Tech 2(R) and requesting module ID. The calibration number will determine if the SDM calibration can be updated or if the SDM will need to be replaced before the new calibration can be installed. Use the table's shown to identify the proper corrective action that is required. If the vehicle has one of the current production calibrations listed below, DO NOT replace the SDM and DO NOT reprogram. If a problem still exists, it is not caused by a calibration error. Use normal diagnostics to correct the condition. The new calibrations are currently available in TIS version 6.0 (or later) or on TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start > Page 1401 Warranty Information For vehicles repaired under warranty, use only one of the labor operations shown. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 1407 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 1408 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start Air Bag Control Module: All Technical Service Bulletins Restraints - Pass. Seat Belt Lamp ON/After Remote Start Bulletin No.: 06-09-40-002 Date: July 13, 2006 TECHNICAL Subject: Passenger Safety Belt Reminder Light Remains On After Remote Start (Perform Appropriate Corrective Action Below)) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Remote Start (RPO AP3) Condition Some customers may comment that the passenger safety belt reminder light remains on with the passenger seatbelt buckled after a remote start. Cause This condition may be caused by a software anomaly within the SDM. Correction Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start > Page 1413 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start > Page 1414 It is important that you first identify the calibration number that is in the SDM. This can be done using the Tech 2(R) and requesting module ID. The calibration number will determine if the SDM calibration can be updated or if the SDM will need to be replaced before the new calibration can be installed. Use the table's shown to identify the proper corrective action that is required. If the vehicle has one of the current production calibrations listed below, DO NOT replace the SDM and DO NOT reprogram. If a problem still exists, it is not caused by a calibration error. Use normal diagnostics to correct the condition. The new calibrations are currently available in TIS version 6.0 (or later) or on TIS2WEB. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-09-40-002 > Jul > 07 > Restraints - Pass. Seat Belt Lamp ON/After Remote Start > Page 1415 Warranty Information For vehicles repaired under warranty, use only one of the labor operations shown. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1416 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) (Except RPO Code ASF) (Pin 1 To 19) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1417 Inflatable Restraint Sensing And Diagnostic Module (SDM) (Except RPO Code ASF) (Pin 20 To 60) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1418 Inflatable Restraint Sensing And Diagnostic Module (SDM) (With RPO Code ASF) (Pin 1 To 16) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1419 Inflatable Restraint Sensing And Diagnostic Module (SDM)(With RPO Code ASF) (Pin 17 To 60) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1420 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the Supplemental Inflatable Restraint (SIR) System. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR System status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR System electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that battery voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR System for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1421 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1422 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 07-09-41-002 > Jan > 07 > SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: Customer Interest SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 07-09-41-002 > Jan > 07 > SRS - Air Bag Lamp ON/DTC B0081 Set > Page 1431 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-09-41-002 > Jan > 07 > SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-09-41-002 > Jan > 07 > SRS - Air Bag Lamp ON/DTC B0081 Set > Page 1437 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-08-64-026B > Oct > 06 > Body - Rear Door Window Seal Molding is Loose Window Seal: All Technical Service Bulletins Body - Rear Door Window Seal Molding is Loose Subject: Rear Door Outer Belt Sealing Strip/Molding Bowed, Loose (Replace with New Design Outer Belt Sealing Strip/Molding) # 06-08-64-026B - (10/10/2006) Models: 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali This bulletin is being revised to add models and parts information. Please discard Corporate Bulletin Number 06-08-64-026A (Section 08 -- Body and Accessories). Condition Some customers may comment that the molding on the rear door window opening is loose on the right or the left rear door. Cause A lack of adhesive between the window run channel and the outer belt sealing strip may cause this condition. Correction Replace the rear door glass outer belt molding sealing strip using the following procedure. 1. Lower the door glass. 2. Pull out and upward on the sealing strip end to unhook it from the door frame. 3. If necessary, with a trim stick, push up on the belt sealing strip to remove it from the door. 4. With a plastic trim stick, pull out the door glass run channel from the rear of the door. 5. Install the new outer belt sealing strip on the door. The picture above shows the back side of the new molding. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-08-64-026B > Oct > 06 > Body - Rear Door Window Seal Molding is Loose > Page 1443 6. Install the plastic tab into the slot in the door as seen in the illustration above. 7. Install the run channel and return the glass to the closed position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-08-64-026B > Oct > 06 > Body - Rear Door Window Seal Molding is Loose > Page 1449 6. Install the plastic tab into the slot in the door as seen in the illustration above. 7. Install the run channel and return the glass to the closed position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Diagrams Compressor/Pump Relay: Diagrams Automatic Level Control Connector End Views Automatic Level Control (ALC) Relay Automatic Level Control (ALC) Relay Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Electronic Suspension Control Component Views Above the Spare Tire 1 - RR Coil Spring 2 - Electrical Suspension Control (ESC) Module (Z55) 3 - Chassis Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 1462 Suspension Control Module: Diagrams Electronic Suspension Control Connector End Views Electronic Suspension Control (ESC) Module Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 1463 Electronic Suspension Control (ESC) Module Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 1464 Suspension Control Module: Service and Repair Electronic Suspension Control Module Replacement Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 1465 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Page 1471 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information > Page 1476 Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Valve Stem Information Bulletin No.: 07-03-10-011 Date: September 20, 2007 INFORMATION Subject: Information on TPM Sensor Valve Stem Appearance (Metal vs. Rubber Stem) and Available Substitute Sensor Models: 2007 Cadillac Escalade, Escalade ESV 2007 Chevrolet Suburban, Tahoe 2007 GMC Yukon, Yukon XL TPM Visual Identification The 2007 Utility models listed above manufactured prior to October 2006 were built with tire pressure monitoring (TPM) sensors that have an aluminum valve stem and an externally visible retaining nut as shown above. This first design sensor has a valve stem that is integral to the body of the sensor. This first design sensor is no longer available for service. To improve serviceability, vehicles built after October 2006 were built with TPM sensors that have a replaceable black rubber valve stem, P/N 25799331, held on by a small TORX(R) fastener as shown above. A service kit is available, P/N 15263240, to service the black rubber valve individually from the sensor, extending the useful life of the sensor. These second design sensors are physically and electronically interchangeable. TPM Appearance Concerns and Available Substitute Sensor Customers of vehicles originally equipped with the metal valve stem TPM sensor may object to the visual difference in the replacement black rubber style of sensor. In these cases, it is acceptable to alternately use TPM sensor, P/N 15268606. This sensor has a metal stem visually very similar to the original style used for pre-October 2006 builds. This sensor does not appear in the electronic Parts Catalog as applicable for these vehicles, however it is electrically compatible and will function correctly in this application. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information > Page 1477 Parts Information Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information > Page 1478 Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System Sensor/Wheel Compatibility Bulletin No.: 06-03-16-001 Date: August 17, 2006 INFORMATION Subject: Tire Pressure Monitor (TPM) Sensors for GM Accessory and Aftermarket Wheels/Tires Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali. Yukon Denali XL Some customers may elect to purchase GM Accessory wheels/tires or aftermarket wheels/tires that require the proper tire pressure sensors to be installed in each wheel and tire assembly. The 2007 model year full-size trucks require unique tire pressure sensors which are not interchangeable with past model year sensors or with other GM models not listed above. Installing the wrong tire pressure sensors in any road wheel will cause a "Service Tire Pressure" message and one or more DTCs to set. All 2007 models listed above were shipped from the assembly plant(s) with the proper tire pressure sensors installed in each wheel/tire assembly and the sensors were properly programmed to the vehicle. Each sensor has its own unique ID code that can be displayed on the J-46079 special tool. Part numbers of compatible TPM sensors are as follows: - 15825475 - this sensor comes shipped from the assembly plant (black, TRW). This sensor can also be obtained in a 16 Pack as 19157606. - 15268606 - this is a compatible sensor for the 2007 full-size trucks (green, Schrader). This sensor is also used on 2007 Impala, Monte Carlo and DTS models. This sensor can also be obtained in a 16 Pack as 19155710. - 15114379 - this is NOT compatible with the 2007 model year full-size trucks. This is the sensor for 2006 and earlier trucks. Dealers who experience TPM problems after the installation of GM accessory wheels/tires or aftermarket wheels/tires should verify that the tire pressure sensors are the correct part number sensor for the vehicle and can communicate with the J-46079. If the J-46079 displays the individual tire pressure sensor IDs, but the vehicle will not learn the sensors, dealers should use the "simulate" feature on the J-46079. In the "simulate" mode, the J-46079 transmits four unique "test" IDs to the vehicle. This allows the user to test the vehicle's ability to learn tire pressure sensors. The "test" IDs sent by the tool are for test purposes only. Valid sensor IDs must be pre-programmed into the vehicle after the "simulate" mode has been used. Testing the Vehicle's Ability to Learn Using the "Simulate" Feature on the J-46079 1. Turn ON the ignition with the engine OFF. 2. Apply the parking brake. Important: If the learn module cannot be enabled, ensure that the TPM system is enabled in the RCDLR. Refer to Control Module Setup in SI. Using the driver information center (DIC), press the vehicle information button until the RELEARN TIRE POSITIONS message displays. If the vehicle does not have the DIC buttons, press the trip odometer reset stem located on the instrument panel cluster until the RELEARN TIRE POSITIONS message displays. If the vehicle has the DIC buttons, press the set/reset button. The horn will sound twice to indicate the TPMs receiver is ready, and the TIRE LEARNING ACTIVE message will display. If the vehicle does not have the DIC buttons, press and hold the trip odometer reset stem until the horn chirps twice and the TIRE LEARNING ACTIVE message is displayed. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information > Page 1479 Alternate method: Lower the driver's window and simultaneously press the keyless entry transmitters lock and unlock buttons until a horn chirp sounds. A horn chirp will sound indicating the learn mode has been enabled. 3. Place the J-46079 in the "simulate" mode. Follow the tool prompts and program all tour tire positions into the vehicle. A horn single chirp will follow the programming for each position. A double horn chirp will indicate the learning sequence has been successful. When you have successfully used the "simulate" mode, the tool will display the simulated sensor IDs and tire pressure for each tire position. Tip: The tire pressures displayed by the tool will not agree with the tire pressures displayed by the DIC. This is an anomaly with the tool software and does not indicate a problem. A double horn chirp after the fourth tire is programmed indicates that the vehicle can learn TPM sensors. Warranty Information Warranty claims should not be submitted for incorrect tire pressure sensors found in GM Accessory wheel/tire assemblies. Incorrect sensors assembled into GM Accessory wheels/tires or aftermarket wheels/tires by GM dealers or other sources are the responsibility of the installer or vehicle owner. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Control Module: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Park Neutral Position (PNP) Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 1485 Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70 2 - Park/Neutral Position (PNP) Switch C175 C175 1 - Automatic Transmission 2 - C175 Vehicle Speed Sensor (VSS) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 1486 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Transmission Control Module (TCM) Transmission Control Module (TCM) 1 - Engine Harness 2 - Transmission Control Module (TCM) 3 - Transmission Control Module (TCM) Connector Harness Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Transmission Control Module (TCM), Engine Side Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1489 Transmission Control Module (TCM), Engine Side Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1490 Control Module: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1491 Transmission Control Module (TCM), Engine Side Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Control Module Replacement Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1494 Control Module: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1495 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-04-21-001 > May > 09 > Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-04-21-001 > May > 09 > Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set > Page 1505 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-04-21-002 > Oct > 07 > Drivetrain - Service 4WD Message/DTC C0378 Set Control Module: Customer Interest Drivetrain - Service 4WD Message/DTC C0378 Set Bulletin No.: 07-04-21-002 Date: October 29, 2007 TECHNICAL Subject: Intermittent Service 4 Wheel Drive Message Displayed in DIC, DTC C0378 Set (Diagnose and Reprogram Transfer Case Control Module (TCCM), if Necessary) Models: 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL with NVG246 Transfer Case (RPO NP8) Condition Some customers may comment on a "SERVICE 4 WHEEL DRIVE" message displayed in the DIC. Upon investigation, the technician may find DTC C0378 set in history or as current. Cause With the transfer case selector switch in either AUTO or 4WD, the front axle actuator can retract on key on. Then when the transfer case control module (TCCM) powers up, it extends back to the 4WD position. On 2007 model utilities, the control loop is faster than previous models, and the actuator may not make it back to 2WD mode and therefore does not advance forward after start up. This "Creep" can lead to an intermittent or no connection on the feedback circuit. There is nothing wrong with the actuators. It is possible that after successive key on cycles, the "SERVICE 4 WHEEL DRIVE" message could be displayed, with DTC C0378 set. Correction Inspect the front axle for proper mechanical engagement. Inspect pin terminal tension at the front axle actuator, connector C2 at the TCCM, C109 and C110. Refer to SI for the connector locations. If the front axle engages properly, and there are no connector problems, update the TCCM with the latest calibration available on TIS2WEB. Customers should be advised that their vehicle should normally be driven in 2WD mode, using Auto Mode or 4WD when weather and road conditions are appropriate. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-04-21-002 > Oct > 07 > Drivetrain - Service 4WD Message/DTC C0378 Set > Page 1510 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 09-04-21-001 > May > 09 > Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 09-04-21-001 > May > 09 > Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set > Page 1516 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-04-21-002 > Oct > 07 > Drivetrain - Service 4WD Message/DTC C0378 Set Control Module: All Technical Service Bulletins Drivetrain - Service 4WD Message/DTC C0378 Set Bulletin No.: 07-04-21-002 Date: October 29, 2007 TECHNICAL Subject: Intermittent Service 4 Wheel Drive Message Displayed in DIC, DTC C0378 Set (Diagnose and Reprogram Transfer Case Control Module (TCCM), if Necessary) Models: 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL with NVG246 Transfer Case (RPO NP8) Condition Some customers may comment on a "SERVICE 4 WHEEL DRIVE" message displayed in the DIC. Upon investigation, the technician may find DTC C0378 set in history or as current. Cause With the transfer case selector switch in either AUTO or 4WD, the front axle actuator can retract on key on. Then when the transfer case control module (TCCM) powers up, it extends back to the 4WD position. On 2007 model utilities, the control loop is faster than previous models, and the actuator may not make it back to 2WD mode and therefore does not advance forward after start up. This "Creep" can lead to an intermittent or no connection on the feedback circuit. There is nothing wrong with the actuators. It is possible that after successive key on cycles, the "SERVICE 4 WHEEL DRIVE" message could be displayed, with DTC C0378 set. Correction Inspect the front axle for proper mechanical engagement. Inspect pin terminal tension at the front axle actuator, connector C2 at the TCCM, C109 and C110. Refer to SI for the connector locations. If the front axle engages properly, and there are no connector problems, update the TCCM with the latest calibration available on TIS2WEB. Customers should be advised that their vehicle should normally be driven in 2WD mode, using Auto Mode or 4WD when weather and road conditions are appropriate. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-04-21-002 > Oct > 07 > Drivetrain - Service 4WD Message/DTC C0378 Set > Page 1521 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1522 Control Module: Locations (1) I/P Trim (2) I/P Cluster Trim (3) Floor Panel (4) Junction Block - Left I/P (5) Body Control Module (BCM) (6) Transfer Case Shift Control Module (NP8) (7) Fuse Block - I/P Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1523 Control Module: Diagrams Transfer Case Control Connector End Views Transfer Case Shift Control Module C1 Transfer Case Shift Control Module C1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1524 Transfer Case Shift Control Module C1 Transfer Case Shift Control Module C2 Transfer Case Shift Control Module C2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1525 Transfer Case Shift Control Module C2 Transfer Case Shift Control Module C3 Transfer Case Shift Control Module C3 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1526 Transfer Case Shift Control Module C3 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1527 Control Module: Service and Repair Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1528 1. If a NEW control module is being installed, program the new module. Refer to Control Module References. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Fuse Block - Underhood, Label Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Diagrams Headlamp Washer Fluid Pump Relay (With RPO Code CE4) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Ajar Switch (With RPO Codes AP3/AP8) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair Integrated Accessory Switch Assembly: Service and Repair ACCESSORY SWITCH REPLACEMENT (EXCEPT CADILLAC) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-127-001B > Jun > 10 > Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: Customer Interest Park Assist System - Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-127-001B > Jun > 10 > Park Assist System - Inoperative/Lamp ON/DTC's Set > Page 1553 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 08-08-127-001B > Jun > 10 > Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: All Technical Service Bulletins Park Assist System Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 08-08-127-001B > Jun > 10 > Park Assist System - Inoperative/Lamp ON/DTC's Set > Page 1559 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 07-08-49-014A > Jul > 08 > Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Distance Sensor: > 07-08-49-014A > Jul > 08 > Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1569 Parking Assist Distance Sensor: Locations Rear Of The Vehicle (With RPO Codes X88,E52) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1570 Rear Of The Vehicle (With RPO Code Z75,Withuout RPO Code E52) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1571 Rear Of The Vehicle (With RPO Code X88,Except RPO Code E52) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1572 Rear Of The Vehicle (With RPO Codes Z75,E52) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1573 Parking Assist Distance Sensor: Diagrams Object Sensor - LR Corner (With RPO Code UD7) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1574 Object Sensor - LR Middle(With RPO Code UD7) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1575 Object Sensor - RR Corner (With RPO Code UD7) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1576 Object Sensor - RR Middle (With RPO Code UD7) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement REAR OBJECT SENSOR HOUSING REPLACEMENT 1. Remove the rear fascia. 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. 4. IMPORTANT: Do Not grind off alignment tabs. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 1579 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 1580 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the rear fascia. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 1581 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement REAR OBJECT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove rear bumper fascia. 2. Disconnect electrical from the rear object sensor. 3. Lift the locking tabs on the housing and remove the rear object sensor. INSTALLATION PROCEDURE 1. IMPORTANT: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems. 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gages. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 1582 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. 5. Install the rear bumper fascia. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Traction Control/Rear Object Detection Switch (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 1586 Parking Assist Switch: Service and Repair REAR OBJECT ALARM MODULE SWITCH REPLACEMENT (TAHOE/YUKON) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations Pedal Assemblies Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations > Page 1590 Pedal Positioning Sensor: Service and Repair BRAKE PEDAL POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the driver knee bolster. 2. Remove the fuse block cover. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor bolts (2). 5. Remove the brake pedal position sensor (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the brake pedal position sensor (3) to the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations > Page 1591 2. NOTE: Refer to Fastener Notice in Service Precautions. Install the brake pedal position sensor bolts (2). Tighten the bolts to 9 N.m (80 lb in). 3. Connect the brake pedal position sensor electrical connector (1). 4. Install the fuse block cover. 5. Install the driver knee bolster. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Diagrams Pedal Positioning Switch: Diagrams I/P Multifunction Switch Assembly (With RPO Codes X88/Z88) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Diagrams > Page 1595 I/P Multifunction Switch Assembly (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair STEERING WHEEL CONTROL SWITCH ASSEMBLY REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair > Page 1603 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Ajar Switch (With RPO Codes AP3/AP8) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations Pedal Assemblies Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations > Page 1612 Pedal Positioning Sensor: Service and Repair BRAKE PEDAL POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the driver knee bolster. 2. Remove the fuse block cover. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor bolts (2). 5. Remove the brake pedal position sensor (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the brake pedal position sensor (3) to the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations > Page 1613 2. NOTE: Refer to Fastener Notice in Service Precautions. Install the brake pedal position sensor bolts (2). Tighten the bolts to 9 N.m (80 lb in). 3. Connect the brake pedal position sensor electrical connector (1). 4. Install the fuse block cover. 5. Install the driver knee bolster. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Diagrams Pedal Positioning Switch: Diagrams I/P Multifunction Switch Assembly (With RPO Codes X88/Z88) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Diagrams > Page 1617 I/P Multifunction Switch Assembly (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) Power Door Lock Switch: Diagrams Driver Door Switch (DDS) Driver Door Switch (DDS) C1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1622 Driver Door Switch (DDS) C2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1623 Driver Door Switch (DDS) C3 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1624 Driver Door Switch (DDS) C4 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1625 Driver Door Switch (DDS) C7 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1626 Power Door Lock Switch: Diagrams Passenger Door Switch (PDS) Passenger Door Switch (PDS) C1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1627 Passenger Door Switch (PDS) C2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1628 Passenger Door Switch (PDS) C3 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1629 Passenger Door Switch (PDS) C4 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Door Switch (DDS) > Page 1630 Passenger Door Switch (PDS) C7 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side DOOR LOCK AND SIDE WINDOW SWITCH REPLACEMENT - DRIVER Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side > Page 1633 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side DOOR LOCK AND SIDE WINDOW SWITCH REPLACEMENT - PASSENGER Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 1642 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 1648 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams Seat Recline Position Sensor - Driver (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-50-011A > Apr > 11 > Body Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-50-011A > Apr > 11 > Body Sticking/Binding Door Mounted Seat Switches > Page 1660 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-50-012 > Oct > 06 > Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: Customer Interest Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 1670 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-50-012 > Oct > 06 > Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: All Technical Service Bulletins Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses Power Trunk / Liftgate Hazard Sensor: All Technical Service Bulletins Body - Power Liftgate Opens Part Way Then Reverses TECHNICAL Bulletin No.: 07-08-47-005B Date: April 28, 2009 Subject: Power Liftgate May Open or Close About a Third of the Way Then Reverses, DTCs B153B, B153E and/or B153F Set (Inspect Liftgate Wiring Harness and Repair as Necessary) Models: 2007-2009 Cadillac Escalade, Escalade ESV 2007-2009 Chevrolet Suburban, Tahoe 2007-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Power Lift Gate (RPO E61) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to change the diagnostic code information. Please discard Corporate Bulletin Number 07-08-47-005A (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the power liftgate opens about a third of the way and then reverses to the closed position. Other customers may comment that when the power liftgate is open, the liftgate starts to close about a third of the way and then reopens. The technician may find diagnostic trouble codes (DTCs) B153B-Liftgate Open Switch Signal Circuit, B153E-Liftgate Position Sensor Signal Circuit and/or B153F-Liftgate Object Sensor Signal Circuit set. Cause The cause may be a sharp sheet metal edge inside the inner roof panel chafing the liftgate wiring harness. Correction Inspect the liftgate wiring harness and repair as necessary using the steps below. 1. Verify the condition and check for any DTCs. 2. Remove the rear door upper garnish molding and retainers. Refer to Rear Door Upper Garnish Molding Replacement in SI. 3. Remove the headliner push retainers. Important Do not fold or crease the headliner panel. 4. Slightly pull down on the center of the headliner panel. 5. Locate connector C405/X405, which is a light gray 22-way connector located under the center of the rear headliner panel. Tip Use a shop towel when disconnecting the rear washer hose to help absorb any washer fluid that may leak. 6. Disconnect the C405/X405 connector and the rear wiper washer hose. 7. Remove the wiring harness pass through retainer, wiring harness, C405/X405 connector and the washer hose from the roof panel. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1680 8. Visually inspect the liftgate wiring harness as shown above and repair any damaged wires. Refer to Wiring Repairs in SI. Important After repairing the wires, wrap the wiring harness with electrical tape and install conduit. 9. Install a piece of Kent-P92565, wire harness wrap 18 mm (3/4 in) inside diameter (I.D.) by 145 mm (53/4 in) length or equivalent flexible conduit to the liftgate wiring harness. 10. Install two pieces of Kent-KT13080, Posi-Seal Plus(TM) or equivalent of electrical moisture sealant pad to the lower inner flange (1) inside the roof panel. 11. Install the liftgate connector C405/X405, wiring harness and the rear washer wiper hose back through the roof panel. 12. Connect the C405/X405 connector, the rear wiper washer hose and seat the wiring harness pass through retainer. 13. Clear any DTCs. 14. Open and close the power rear liftgate ten complete cycles. 15. Install the headliner push retainers. 16. Install the rear door upper garnish molding. 17. Verify that the condition has been fixed. Parts Information Order Kent*-KT13080, Posi-Seal Plus(TM) and P92565, Wire Harness Wrap from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1681 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1687 8. Visually inspect the liftgate wiring harness as shown above and repair any damaged wires. Refer to Wiring Repairs in SI. Important After repairing the wires, wrap the wiring harness with electrical tape and install conduit. 9. Install a piece of Kent-P92565, wire harness wrap 18 mm (3/4 in) inside diameter (I.D.) by 145 mm (53/4 in) length or equivalent flexible conduit to the liftgate wiring harness. 10. Install two pieces of Kent-KT13080, Posi-Seal Plus(TM) or equivalent of electrical moisture sealant pad to the lower inner flange (1) inside the roof panel. 11. Install the liftgate connector C405/X405, wiring harness and the rear washer wiper hose back through the roof panel. 12. Connect the C405/X405 connector, the rear wiper washer hose and seat the wiring harness pass through retainer. 13. Clear any DTCs. 14. Open and close the power rear liftgate ten complete cycles. 15. Install the headliner push retainers. 16. Install the rear door upper garnish molding. 17. Verify that the condition has been fixed. Parts Information Order Kent*-KT13080, Posi-Seal Plus(TM) and P92565, Wire Harness Wrap from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1688 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1689 Power Seat Switch: Locations Driver Seat Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1690 Passenger Seat Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1691 Driver Seat Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1692 Passenger Seat Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch Power Seat Switch: Diagrams Folding Seat Switch Folding Seat Switch - Front (With RPO Code ARS) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1695 Folding Seat Switch - LR (With RPO Code ARS) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1696 Folding Seat Switch - RR (With RPO Code ARS) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1697 Power Seat Switch: Diagrams Seat Adjuster Switch Seat Adjuster Switch - Driver (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1698 Seat Adjuster Switch - Driver (Except RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1699 Seat Adjuster Switch - Passenger (Except RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1700 Seat Adjuster Switch - Passenger (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1701 Power Seat Switch: Diagrams Seat Lumbar Switch Seat Lumbar Switch - Driver (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Folding Seat Switch > Page 1702 Seat Lumbar Switch - Passenger (With RPO Code AN3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Front Seat Adjuster Switch Knob Replacement FRONT SEAT ADJUSTER SWITCH KNOB REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1705 Power Seat Switch: Service and Repair Power Seat Switch Replacement POWER SEAT SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1706 Power Seat Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement DRIVER SEAT ADJUSTER MEMORY SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1707 Power Seat Switch: Service and Repair Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1708 Power Seat Switch: Service and Repair Front Seat Adjuster Switch Knob Replacement FRONT SEAT ADJUSTER SWITCH KNOB REPLACEMENT Power Seat Switch Replacement POWER SEAT SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1709 Driver Seat Adjuster Memory Switch Replacement DRIVER SEAT ADJUSTER MEMORY SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1710 Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1711 Rear Seat Recliner Switch Replacement - Overhead Console REAR SEAT RECLINER SWITCH REPLACEMENT - OVERHEAD CONSOLE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1712 Rear Seat Recliner Switch Replacement - Lock Pillar Trim REAR SEAT RECLINER SWITCH REPLACEMENT - LOCK PILLAR TRIM Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 1713 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Hazard Sensor: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses Power Trunk / Liftgate Hazard Sensor: Customer Interest Body - Power Liftgate Opens Part Way Then Reverses TECHNICAL Bulletin No.: 07-08-47-005B Date: April 28, 2009 Subject: Power Liftgate May Open or Close About a Third of the Way Then Reverses, DTCs B153B, B153E and/or B153F Set (Inspect Liftgate Wiring Harness and Repair as Necessary) Models: 2007-2009 Cadillac Escalade, Escalade ESV 2007-2009 Chevrolet Suburban, Tahoe 2007-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Power Lift Gate (RPO E61) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to change the diagnostic code information. Please discard Corporate Bulletin Number 07-08-47-005A (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the power liftgate opens about a third of the way and then reverses to the closed position. Other customers may comment that when the power liftgate is open, the liftgate starts to close about a third of the way and then reopens. The technician may find diagnostic trouble codes (DTCs) B153B-Liftgate Open Switch Signal Circuit, B153E-Liftgate Position Sensor Signal Circuit and/or B153F-Liftgate Object Sensor Signal Circuit set. Cause The cause may be a sharp sheet metal edge inside the inner roof panel chafing the liftgate wiring harness. Correction Inspect the liftgate wiring harness and repair as necessary using the steps below. 1. Verify the condition and check for any DTCs. 2. Remove the rear door upper garnish molding and retainers. Refer to Rear Door Upper Garnish Molding Replacement in SI. 3. Remove the headliner push retainers. Important Do not fold or crease the headliner panel. 4. Slightly pull down on the center of the headliner panel. 5. Locate connector C405/X405, which is a light gray 22-way connector located under the center of the rear headliner panel. Tip Use a shop towel when disconnecting the rear washer hose to help absorb any washer fluid that may leak. 6. Disconnect the C405/X405 connector and the rear wiper washer hose. 7. Remove the wiring harness pass through retainer, wiring harness, C405/X405 connector and the washer hose from the roof panel. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Hazard Sensor: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1722 8. Visually inspect the liftgate wiring harness as shown above and repair any damaged wires. Refer to Wiring Repairs in SI. Important After repairing the wires, wrap the wiring harness with electrical tape and install conduit. 9. Install a piece of Kent-P92565, wire harness wrap 18 mm (3/4 in) inside diameter (I.D.) by 145 mm (53/4 in) length or equivalent flexible conduit to the liftgate wiring harness. 10. Install two pieces of Kent-KT13080, Posi-Seal Plus(TM) or equivalent of electrical moisture sealant pad to the lower inner flange (1) inside the roof panel. 11. Install the liftgate connector C405/X405, wiring harness and the rear washer wiper hose back through the roof panel. 12. Connect the C405/X405 connector, the rear wiper washer hose and seat the wiring harness pass through retainer. 13. Clear any DTCs. 14. Open and close the power rear liftgate ten complete cycles. 15. Install the headliner push retainers. 16. Install the rear door upper garnish molding. 17. Verify that the condition has been fixed. Parts Information Order Kent*-KT13080, Posi-Seal Plus(TM) and P92565, Wire Harness Wrap from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Hazard Sensor: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1723 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Hazard Sensor: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses Power Trunk / Liftgate Hazard Sensor: All Technical Service Bulletins Body - Power Liftgate Opens Part Way Then Reverses TECHNICAL Bulletin No.: 07-08-47-005B Date: April 28, 2009 Subject: Power Liftgate May Open or Close About a Third of the Way Then Reverses, DTCs B153B, B153E and/or B153F Set (Inspect Liftgate Wiring Harness and Repair as Necessary) Models: 2007-2009 Cadillac Escalade, Escalade ESV 2007-2009 Chevrolet Suburban, Tahoe 2007-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Power Lift Gate (RPO E61) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to change the diagnostic code information. Please discard Corporate Bulletin Number 07-08-47-005A (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the power liftgate opens about a third of the way and then reverses to the closed position. Other customers may comment that when the power liftgate is open, the liftgate starts to close about a third of the way and then reopens. The technician may find diagnostic trouble codes (DTCs) B153B-Liftgate Open Switch Signal Circuit, B153E-Liftgate Position Sensor Signal Circuit and/or B153F-Liftgate Object Sensor Signal Circuit set. Cause The cause may be a sharp sheet metal edge inside the inner roof panel chafing the liftgate wiring harness. Correction Inspect the liftgate wiring harness and repair as necessary using the steps below. 1. Verify the condition and check for any DTCs. 2. Remove the rear door upper garnish molding and retainers. Refer to Rear Door Upper Garnish Molding Replacement in SI. 3. Remove the headliner push retainers. Important Do not fold or crease the headliner panel. 4. Slightly pull down on the center of the headliner panel. 5. Locate connector C405/X405, which is a light gray 22-way connector located under the center of the rear headliner panel. Tip Use a shop towel when disconnecting the rear washer hose to help absorb any washer fluid that may leak. 6. Disconnect the C405/X405 connector and the rear wiper washer hose. 7. Remove the wiring harness pass through retainer, wiring harness, C405/X405 connector and the washer hose from the roof panel. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Hazard Sensor: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1729 8. Visually inspect the liftgate wiring harness as shown above and repair any damaged wires. Refer to Wiring Repairs in SI. Important After repairing the wires, wrap the wiring harness with electrical tape and install conduit. 9. Install a piece of Kent-P92565, wire harness wrap 18 mm (3/4 in) inside diameter (I.D.) by 145 mm (53/4 in) length or equivalent flexible conduit to the liftgate wiring harness. 10. Install two pieces of Kent-KT13080, Posi-Seal Plus(TM) or equivalent of electrical moisture sealant pad to the lower inner flange (1) inside the roof panel. 11. Install the liftgate connector C405/X405, wiring harness and the rear washer wiper hose back through the roof panel. 12. Connect the C405/X405 connector, the rear wiper washer hose and seat the wiring harness pass through retainer. 13. Clear any DTCs. 14. Open and close the power rear liftgate ten complete cycles. 15. Install the headliner push retainers. 16. Install the rear door upper garnish molding. 17. Verify that the condition has been fixed. Parts Information Order Kent*-KT13080, Posi-Seal Plus(TM) and P92565, Wire Harness Wrap from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Hazard Sensor: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 1730 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > Page 1731 Power Trunk / Liftgate Hazard Sensor: Diagrams Liftgate Object Sensor - Left (With RPO Code E61) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Technical Service Bulletins > Page 1732 Liftgate Object Sensor - Right (With RPO Code E61) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Power Liftgate Switch (With RPO Code E61) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 1736 Power Trunk / Liftgate Lock Switch: Service and Repair LIFTGATE ACTUATOR SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Fan Switch > Component Information > Service and Repair Seat Fan Switch: Service and Repair HEATED AND COOLED SEAT SWITCH REPLACEMENT (With RPO Code KB6) The heated seat switch is not a serviceable unit. The heated seat switch is part of the HVAC control module and must be replaced as an assembly. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement (Without RPO Code KB6) Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement (Without RPO Code KB6) FRONT SEAT HEATER SWITCH REPLACEMENT (WITHOUT RPO CODE KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement (Without RPO Code KB6) > Page 1744 Seat Heater Switch: Service and Repair Heated and Cooled Seat Switch Replacement (With RPO Code KB6) HEATED AND COOLED SEAT SWITCH REPLACEMENT (With RPO Code KB6) The heated seat switch is not a serviceable unit. The heated seat switch is part of the HVAC control module and must be replaced as an assembly. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Service and Repair Seat Memory Switch: Service and Repair DRIVER SEAT ADJUSTER MEMORY SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Top Front Of The Passenger Compartment Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1751 Sunroof Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1752 Sunroof / Moonroof Switch: Service and Repair SUNROOF SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Trunk / Liftgate Switch: Diagrams Liftgate Close Switch (With RPO Code E61) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1756 Liftgate Handle Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1757 Liftglass Release Switch (With RPO Code E52) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1758 Trunk / Liftgate Switch: Service and Repair LIFTGATE RELEASE SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Position Sensor > Component Information > Service and Repair Trunk / Liftgate Position Sensor: Service and Repair LIFTGATE SIDE UPPER SENSOR REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations Hydraulic Brake Component Views 1 - Windshield Wiper Motor 2 - Power Brake Booster 3 - Windshield Washer Solvent Heater 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) 7 - Brake Booster Vacuum Sensor 8 - Brake Fluid Level Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 1766 Brake Booster Vacuum Sensor: Diagrams Antilock Brake System Connector End Views Brake Booster Vacuum Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 1767 Brake Booster Vacuum Sensor: Service and Repair POWER BRAKE BOOSTER VACUUM SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the chassis wiring harness electrical connector (1) from the brake booster vacuum sensor. 2. Remove the brake booster vacuum sensor from the brake booster. 3. Remove the brake booster vacuum sensor grommet from the brake booster. INSTALLATION PROCEDURE IMPORTANT: Lightly coat the brake booster vacuum sensor grommet with clean engine oil before installing the sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 1768 1. Install the brake booster vacuum sensor grommet to the brake booster. 2. Install the brake booster vacuum sensor to the brake booster. 3. Connect the chassis wiring harness electrical connector (1) to the brake booster vacuum sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Hydraulic Brake Component Views 1 - Windshield Wiper Motor 2 - Power Brake Booster 3 - Windshield Washer Solvent Heater 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) 7 - Brake Booster Vacuum Sensor 8 - Brake Fluid Level Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1772 Brake Fluid Level Sensor/Switch: Diagrams Hydraulic Brake Connector End Views Brake Fluid Level Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1773 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1774 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Hydraulic Brake Connector End Views Park Brake Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 1778 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Remove the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 1779 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch mounting bolt. Tighten the bolt to 3 N.m (25 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams Traction Control Switch: Diagrams Antilock Brake System Connector End Views Traction Control/Rear Object Detection Switch (Z75) Traction Control/Rear Object Detection Switch (Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 1783 Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Electronic Traction Control Switch Replacement Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 06-05-25-004A > Aug > 07 > TCS/ABS - Rear Wheel Speed Sensor Data Reversed Wheel Speed Sensor: Customer Interest TCS/ABS - Rear Wheel Speed Sensor Data Reversed Bulletin No.: 06-05-25-004A Date: August 06, 2007 INFORMATION Subject: Information on Reprogramming EBCM if Tech 2(R) Data for Rear Wheel Speed Sensors is Reversed Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Built Prior to May 1, 2006 And Less Than 8600 lb GVW Supercede: This bulletin is being revised to include a "built prior to" date and remove the Silverado and Sierra models. Please discard Corporate Bulletin Number 06-05-25-004 (Section 05 - Brakes). When viewing rear wheel speed sensor information via a Tech 2(R), you may notice that the rear wheel speed data is reversed. The Tech 2(R) will show the left wheel speed data as the right on the Tech 2(R) screen and the right wheel speed data as the left. This is the result of the Electronic Brake Traction Control Module (EBCM) sending out the signal to the Tech 2(R) with the data swapped. If this condition is present, DO NOT replace the EBCM. To resolve this concern, reprogram the EBCM with updated calibrations. This new service calibration was released with TIS satellite data update version 5.0. Select EBCM in the TIS2000 supported controller list as the module. As always, make sure that your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-05-25-004A > Aug > 07 > TCS/ABS - Rear Wheel Speed Sensor Data Reversed Wheel Speed Sensor: All Technical Service Bulletins TCS/ABS - Rear Wheel Speed Sensor Data Reversed Bulletin No.: 06-05-25-004A Date: August 06, 2007 INFORMATION Subject: Information on Reprogramming EBCM if Tech 2(R) Data for Rear Wheel Speed Sensors is Reversed Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Suburban, Tahoe 2007 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Built Prior to May 1, 2006 And Less Than 8600 lb GVW Supercede: This bulletin is being revised to include a "built prior to" date and remove the Silverado and Sierra models. Please discard Corporate Bulletin Number 06-05-25-004 (Section 05 - Brakes). When viewing rear wheel speed sensor information via a Tech 2(R), you may notice that the rear wheel speed data is reversed. The Tech 2(R) will show the left wheel speed data as the right on the Tech 2(R) screen and the right wheel speed data as the left. This is the result of the Electronic Brake Traction Control Module (EBCM) sending out the signal to the Tech 2(R) with the data swapped. If this condition is present, DO NOT replace the EBCM. To resolve this concern, reprogram the EBCM with updated calibrations. This new service calibration was released with TIS satellite data update version 5.0. Select EBCM in the TIS2000 supported controller list as the module. As always, make sure that your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1802 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1803 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 1808 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1814 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1815 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 1820 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1821 Wheel Speed Sensor: Diagrams Antilock Brake System Connector End Views Wheel Speed Sensor (WSS) - LF (JH6 Over 8600 GVW) Wheel Speed Sensor (WSS)- LF (JH6 Over 8600 GVW) Wheel Speed Sensor (WSS) - LF (JL4 Under 8600 GVW) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1822 Wheel Speed Sensor (WSS)- LF (JL4 Under 8600 GVW) Wheel Speed Sensor (WSS) - LR Wheel Speed Sensor (WSS)- LR Wheel Speed Sensor (WSS) - RF (JH6 Over 8600 GVW) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1823 Wheel Speed Sensor (WSS) - RF (JL4 Under 8600 GVW) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1824 Wheel Speed Sensor (WSS)- RF (JL4 Under 8600 GVW) Wheel Speed Sensor (WSS) - RR Wheel Speed Sensor (WSS)- RR Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Caution: Refer to Brake Dust Caution. Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. 3. Remove the front disc brake rotor. 4. Remove the wheel speed sensor (WSS) cable mounting clip from the steering knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Disconnect the WSS cable electrical connector. 8. Remove the WSS mounting bolt. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 9. Remove the WSS from the hub/bearing assembly. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 1827 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. Important: Use the lubricant supplied in the WSS kit. Do not substitute another type of grease. 3. Apply a thin layer of lubricant to the hub surface and the WSS O-ring prior to installation. 4. Install the WSS into the hub/bearing assembly. Ensure that the WSS is seated fully against the hub. Notice: Refer to Fastener Notice. 5. Install the WSS mounting bolt. Tighten the WSS mounting bolt to 18 N.m (13 lb ft). Important: Make sure the WSS cable is properly routed, the wire is not twisted and all clips are secure. Do not allow the wire to contact surrounding vehicle components. 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. 10. Install the front disc brake rotor. 11. Install the tire and wheel assembly. 12. Perform the diagnostic system check. Refer to Diagnostic System Check - Vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 1828 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the electrical connector. 3. Remove the wheel speed sensor retaining bolt. 4. Release the wheel speed sensor wiring harness from the retainers. 5. Remove the wheel speed sensor. Installation Procedure 1. Using a twisting motion, install the wheel speed sensor until fully seated. Notice: Refer to Fastener Notice. 2. Install the wheel speed sensor retaining bolt. Tighten the wheel speed sensor retaining bolt to 13 N.m (115 lb in). 3. Connect the electrical connector. 4. Install the wheel speed sensor wiring harness to the retainers. 5. Lower the vehicle. 6. Perform a low speed test to ensure the wheel speed sensor is functioning properly: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 1829 1. Start the engine and allow it to idle. 2. Verify the ABS indicator or the traction assist indicator remains illuminated. 3. If the ABS indicator or the traction assist indicator remains illuminated, DO NOT proceed to drive the vehicle until it is diagnosed and repaired. Check the wheel speed sensor electrical connector to ensure it is not damaged and is installed properly. If the lamp remains illuminated, refer to Symptoms - Antilock Brake System. 4. Select a smooth, dry, clean, and level road or large lot that is as free of traffic and obstacles as possible. 5. Drive the vehicle and maintain a speed of at least 16 km/h (10 mph) for at least 5 seconds. 6. Stop the vehicle and check to see if the ABS indicator or the traction assist indicator is illuminated. 7. If an indicator is illuminated, refer to Diagnostic Starting Point - Antilock Brake System. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 1830 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement Tools Required ^ J 8092 Driver Handle ^ J 21128 Axle Pinion Oil Seal Installer ^ J 23690 Bearing Installer ^ J 2619-01 Slide Hammer ^ J 45857 Tone Wheel and/or Bearing Remover ^ J 45860 Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. 3. Remove the rear wheel speed sensor. 4. Remove the rear axle housing cover. 5. Remove the axle shaft. 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J 45857 (1) and the J 2619-01 (2). Installation Procedure 1. Install the wheel speed sensor ring using the J 45860 (1) and the J 8092 (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 1831 3. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 5. Install the axle shaft seal using the J 21128. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. 8. Install the rear axle housing cover. 9. Install the rear wheel speed sensor. 10. Install the tire and wheel assembly. 11. Fill the rear axle. Refer to Rear Axle Lubricant Replacement. 12. Lower the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams Yaw Rate Sensor: Diagrams Antilock Brake System Connector End Views Yaw Rate and Lateral Acceleration Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 1835 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1846 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1847 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1848 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1849 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1855 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1856 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1857 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1858 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1859 Temperature Versus Resistance Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1860 Front Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1861 Engine Coolant Temperature (ECT) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1862 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (Vac-N-Fill). See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1863 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. 2. NOTE: Refer to Fastener Notice. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Draining and Filling Cooling System (Vac-N-Fill). See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Place a suitable drain pan under the oil pan drain plug. 3. Remove the oil pan drain plug (430). 4. Allow the oil pan to drain completely. 5. Re-install the oil pan drain plug until snug. 6. Remove the drain pan from under the vehicle. 7. Disconnect the engine harness electrical connector (4) from the oil level sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 1868 8. Remove the oil level sensor from the oil pan. Installation Procedure Notice: Refer to Fastener Notice. 1. Install the oil level sensor to the oil pan. Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the engine harness electrical connector (4) to the oil level sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 1869 3. Ensure that the oil pan drain plug is tight. Tighten the drain plug to 25 N.m (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with NEW engine oil. Refer to Fluid and Lubricant Recommendations and Approximate Fluid Capacities. 6. Start the engine and inspect for leaks. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Diagrams Oil Level Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sensor: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks Oil Pressure Sensor: Customer Interest Engine - Low Oil Lamp ON/Oil Leaks TECHNICAL Bulletin No.: 07-06-01-004A Date: November 25, 2008 Subject: All Vortec(R) GEN IV V8 Engines - LY2 LS4 LC9 LH6 LMG LY5 LS2 L76 LY6 L92 LS7, Low Oil Level Indicator Lamp On and/or Engine Oil Leak (Reseal Oil Pressure Sensor) Models Supercede: This bulletin is being updated to include a labor operation number for CTS-V and Corvette models. Please discard Please discard Corporate Bulletin Number 07-06-01-004 (Section 06 Engine/Propulsion System). Condition Some customers may comment on a low oil level indicator lamp on and/or engine oil leak. Upon further investigation, the technician may find that the oil leak is at the oil pressure sensor that is threaded into the valve lifter oil manifold (VLOM) assembly and/or engine valley cover. Correction If the engine oil leak was found to be at the engine oil pressure sensor, then remove the oil pressure sensor and reseal with a pipe sealant with Teflon or equivalent, P/N 12346004 (in Canada, P/N 10953480). Refer to Engine Oil Pressure Sensor and/or Switch Replacement in SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sensor: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks > Page 1884 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sensor: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks Oil Pressure Sensor: All Technical Service Bulletins Engine - Low Oil Lamp ON/Oil Leaks TECHNICAL Bulletin No.: 07-06-01-004A Date: November 25, 2008 Subject: All Vortec(R) GEN IV V8 Engines - LY2 LS4 LC9 LH6 LMG LY5 LS2 L76 LY6 L92 LS7, Low Oil Level Indicator Lamp On and/or Engine Oil Leak (Reseal Oil Pressure Sensor) Models Supercede: This bulletin is being updated to include a labor operation number for CTS-V and Corvette models. Please discard Please discard Corporate Bulletin Number 07-06-01-004 (Section 06 Engine/Propulsion System). Condition Some customers may comment on a low oil level indicator lamp on and/or engine oil leak. Upon further investigation, the technician may find that the oil leak is at the oil pressure sensor that is threaded into the valve lifter oil manifold (VLOM) assembly and/or engine valley cover. Correction If the engine oil leak was found to be at the engine oil pressure sensor, then remove the oil pressure sensor and reseal with a pipe sealant with Teflon or equivalent, P/N 12346004 (in Canada, P/N 10953480). Refer to Engine Oil Pressure Sensor and/or Switch Replacement in SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sensor: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks > Page 1890 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 1891 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 1892 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Sealers, Adhesives, and Lubricants. Notice: Refer to Fastener Notice. 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 N.m (26 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 1893 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 N.m (26 lb ft). 5. Install the intake manifold. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Air Temperature Sensor - HVAC Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Ambient Air Temperature Sensor Replacement Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Ambient Air Temperature Sensor Replacement > Page 1900 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor - With RPO CJ2 AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT (WITH RPO CODE CJ2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Ambient Air Temperature Sensor Replacement > Page 1901 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor - With RPO DF5 AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT (WITH RPO CODE DF5) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Above The Headliner Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1905 Cabin Temperature Sensor / Switch: Diagrams Inside Air Temperature Sensor - Front Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1906 Inside Air Temperature Sensor - Rear Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Assembly Replacement Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Assembly Replacement INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Assembly Replacement > Page 1909 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Assembly Replacement > Page 1910 Cabin Temperature Sensor / Switch: Service and Repair Auxiliary Inside Air Temperature Sensor Assembly Replacement AUXILIARY INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the third pillar molding. 2. Remove the left rear coat hook, if equipped. 3. Remove the rear headliner retainers from the front headliner. 4. Carefully lower the headliner from the roof Velcro retainers. 5. Disconnect the electrical connector from the inside air temperature sensor. 6. Partially remove the auxiliary inside air temperature sensor from the headliner. 7. Remove the sensor grille from the auxiliary inside air temperature sensor. 8. Remove the auxiliary inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Secure the headliner to the roof Velcro. 5. Install the rear headliner retainers to the front headliner. 6. Install the left rear coat hook, if equipped. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Assembly Replacement > Page 1911 7. Install the third pillar molding. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations Discharge Air Temperature Sensor / Switch: Locations Front HVAC Module Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1915 Air Temperature Sensor - Upper Auxiliary Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Lower Discharge Air Temperature Sensor / Switch: Diagrams Air Temperature Sensor - Lower Air Temperature Sensor - Lower Auxiliary (LWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Lower > Page 1918 Air Temperature Sensor - Lower Auxiliary (SWB) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Lower > Page 1919 Air Temperature Sensor - Lower Left Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Lower > Page 1920 Air Temperature Sensor - Lower Right Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Lower > Page 1921 Discharge Air Temperature Sensor / Switch: Diagrams Air Temperature Sensor - Upper Auxiliary Air Temperature Sensor - Upper Auxiliary Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Lower > Page 1922 Air Temperature Sensor - Upper Left Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Lower > Page 1923 Air Temperature Sensor - Upper Right Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Auxiliary (Behr) Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Auxiliary (Behr) AIR TEMPERATURE SENSOR REPLACEMENT - UPPER AUXILIARY (BEHR) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Auxiliary (Behr) > Page 1926 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Auxiliary (Delphi) AIR TEMPERATURE SENSOR REPLACEMENT - LOWER AUXILIARY (DELPHI) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Auxiliary (Behr) > Page 1927 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left Side AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT SIDE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Auxiliary (Behr) > Page 1928 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right Side AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT SIDE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations RR Of The Engine Compartment Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System - Automatic A/C Low Pressure Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 1935 A/C Low Pressure Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 1936 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Install the new O-ring seal to the switch. 2. NOTE: Refer to Fastener Notice. Install the A/C low pressure switch to the accumulator. Tighten the switch to 6 N.m (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams Ambient Light/Sunload Sensor Assembly (With RPO Code CJ2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 1940 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations Front Of The I/P (Except RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 1945 Front Of The I/P (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 1946 Headlamp And Panel Dimmer Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. Door Switch: Customer Interest Electrical - Power Locks/Windows/Courtesy Lamps Inop. Bulletin No.: 06-08-64-014A Date: July 20, 2006 TECHNICAL Subject: Door Locks, Power Windows, Door Courtesy Lamps, Heated/Cooled Seat Indicators Inoperative (Reprogram Driver & Passenger Door Switches) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon Supercede: This bulletin is being revised to include the Lucerne and DTS models. Please discard Corporate Bulletin Number 06-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ Front Door Locks Inoperative ^ Passenger Power Window Inoperative ^ Door Courtesy Lamps Inoperative ^ Heated/Cooled Seat Indicators Inoperative ^ Or any other driver or passenger door function issue that can be resolved by an ignition cycle. Customers may also comment that a vehicle ignition cycle typically cures the symptoms. Cause The cause of these conditions may be due to a software anomaly within the driver and passenger door switches. Correction DO NOT REPLACE THE DRIVER DOOR SWITCH OR PASSENGER DOOR SWITCH. Using SPS and Pass-Thru method, reprogram the driver door switch (DDS) and passenger door switch (PDS) with updated software calibrations. These new service calibrations were released with TIS satellite data update version 2.75 / 2006. As always, make sure your Tech 2(R) is updated with the latest software version. After the reprogramming is completed, check and clear all DTCs that may have set as a result of the programming process. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. > Page 1955 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. Door Switch: All Technical Service Bulletins Electrical - Power Locks/Windows/Courtesy Lamps Inop. Bulletin No.: 06-08-64-014A Date: July 20, 2006 TECHNICAL Subject: Door Locks, Power Windows, Door Courtesy Lamps, Heated/Cooled Seat Indicators Inoperative (Reprogram Driver & Passenger Door Switches) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon Supercede: This bulletin is being revised to include the Lucerne and DTS models. Please discard Corporate Bulletin Number 06-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ Front Door Locks Inoperative ^ Passenger Power Window Inoperative ^ Door Courtesy Lamps Inoperative ^ Heated/Cooled Seat Indicators Inoperative ^ Or any other driver or passenger door function issue that can be resolved by an ignition cycle. Customers may also comment that a vehicle ignition cycle typically cures the symptoms. Cause The cause of these conditions may be due to a software anomaly within the driver and passenger door switches. Correction DO NOT REPLACE THE DRIVER DOOR SWITCH OR PASSENGER DOOR SWITCH. Using SPS and Pass-Thru method, reprogram the driver door switch (DDS) and passenger door switch (PDS) with updated software calibrations. These new service calibrations were released with TIS satellite data update version 2.75 / 2006. As always, make sure your Tech 2(R) is updated with the latest software version. After the reprogramming is completed, check and clear all DTCs that may have set as a result of the programming process. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. > Page 1961 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Diagrams Ambient Air Temperature Sensor - ISRVM Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Hydraulic Brake Connector End Views Park Brake Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 1968 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Remove the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 1969 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch mounting bolt. Tighten the bolt to 3 N.m (25 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations Front Of The I/P (Except RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1974 Front Of The I/P (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1975 Ambient Light Sensor: Diagrams Ambient Light/Sunload Sensor Assembly (With RPO Code CJ2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1976 Ambient Light Sensor (With RPO Code CJ3) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1977 Ambient Light/Sunload Sensor Assembly (With RPO Code CJ2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1978 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 08-08-42-003A > Aug > 09 > Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: Customer Interest Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 08-08-42-003A > Aug > 09 > Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: All Technical Service Bulletins Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1992 Stop Lamp Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (Adjustable Pedal) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Adjustable Pedal) STOP LAMP SWITCH REPLACEMENT (ADJUSTABLE PEDAL) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (Adjustable Pedal) > Page 1995 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Non-Adjustable Pedal) STOP LAMP SWITCH REPLACEMENT (NON-ADJUSTABLE PEDAL) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Front Of The I/P (Except RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1999 Combination Switch: Diagrams I/P Multifunction Switch Assembly (With RPO Code X88/Z88) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 2000 I/P Multifunction Switch Assembly (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 2001 I/P Multifunction Switch Assembly (With RPO Codes X88/Z88) (Pin 1 And 11) I/P Multifunction Switch Assembly (With RPO Codes X88/Z88) (Pin 12) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Dome Lamp Switch: > 08-08-42-004 > Aug > 08 > Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Dome Lamp Switch: > 08-08-42-004 > Aug > 08 > Lighting - Dome/Reading Lamps Inoperative > Page 2010 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Dome Lamp Switch: > 08-08-42-004 > Aug > 08 > Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Dome Lamp Switch: > 08-08-42-004 > Aug > 08 > Lighting - Dome/Reading Lamps Inoperative > Page 2016 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. Door Switch: Customer Interest Electrical - Power Locks/Windows/Courtesy Lamps Inop. Bulletin No.: 06-08-64-014A Date: July 20, 2006 TECHNICAL Subject: Door Locks, Power Windows, Door Courtesy Lamps, Heated/Cooled Seat Indicators Inoperative (Reprogram Driver & Passenger Door Switches) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon Supercede: This bulletin is being revised to include the Lucerne and DTS models. Please discard Corporate Bulletin Number 06-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ Front Door Locks Inoperative ^ Passenger Power Window Inoperative ^ Door Courtesy Lamps Inoperative ^ Heated/Cooled Seat Indicators Inoperative ^ Or any other driver or passenger door function issue that can be resolved by an ignition cycle. Customers may also comment that a vehicle ignition cycle typically cures the symptoms. Cause The cause of these conditions may be due to a software anomaly within the driver and passenger door switches. Correction DO NOT REPLACE THE DRIVER DOOR SWITCH OR PASSENGER DOOR SWITCH. Using SPS and Pass-Thru method, reprogram the driver door switch (DDS) and passenger door switch (PDS) with updated software calibrations. These new service calibrations were released with TIS satellite data update version 2.75 / 2006. As always, make sure your Tech 2(R) is updated with the latest software version. After the reprogramming is completed, check and clear all DTCs that may have set as a result of the programming process. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. > Page 2025 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. Door Switch: All Technical Service Bulletins Electrical - Power Locks/Windows/Courtesy Lamps Inop. Bulletin No.: 06-08-64-014A Date: July 20, 2006 TECHNICAL Subject: Door Locks, Power Windows, Door Courtesy Lamps, Heated/Cooled Seat Indicators Inoperative (Reprogram Driver & Passenger Door Switches) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade 2007 Chevrolet Tahoe 2007 GMC Yukon Supercede: This bulletin is being revised to include the Lucerne and DTS models. Please discard Corporate Bulletin Number 06-08-64-014 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ Front Door Locks Inoperative ^ Passenger Power Window Inoperative ^ Door Courtesy Lamps Inoperative ^ Heated/Cooled Seat Indicators Inoperative ^ Or any other driver or passenger door function issue that can be resolved by an ignition cycle. Customers may also comment that a vehicle ignition cycle typically cures the symptoms. Cause The cause of these conditions may be due to a software anomaly within the driver and passenger door switches. Correction DO NOT REPLACE THE DRIVER DOOR SWITCH OR PASSENGER DOOR SWITCH. Using SPS and Pass-Thru method, reprogram the driver door switch (DDS) and passenger door switch (PDS) with updated software calibrations. These new service calibrations were released with TIS satellite data update version 2.75 / 2006. As always, make sure your Tech 2(R) is updated with the latest software version. After the reprogramming is completed, check and clear all DTCs that may have set as a result of the programming process. Warranty Information Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-64-014A > Jul > 06 > Electrical - Power Locks/Windows/Courtesy Lamps Inop. > Page 2031 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses Power Trunk / Liftgate Hazard Sensor: All Technical Service Bulletins Body - Power Liftgate Opens Part Way Then Reverses TECHNICAL Bulletin No.: 07-08-47-005B Date: April 28, 2009 Subject: Power Liftgate May Open or Close About a Third of the Way Then Reverses, DTCs B153B, B153E and/or B153F Set (Inspect Liftgate Wiring Harness and Repair as Necessary) Models: 2007-2009 Cadillac Escalade, Escalade ESV 2007-2009 Chevrolet Suburban, Tahoe 2007-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Power Lift Gate (RPO E61) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to change the diagnostic code information. Please discard Corporate Bulletin Number 07-08-47-005A (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the power liftgate opens about a third of the way and then reverses to the closed position. Other customers may comment that when the power liftgate is open, the liftgate starts to close about a third of the way and then reopens. The technician may find diagnostic trouble codes (DTCs) B153B-Liftgate Open Switch Signal Circuit, B153E-Liftgate Position Sensor Signal Circuit and/or B153F-Liftgate Object Sensor Signal Circuit set. Cause The cause may be a sharp sheet metal edge inside the inner roof panel chafing the liftgate wiring harness. Correction Inspect the liftgate wiring harness and repair as necessary using the steps below. 1. Verify the condition and check for any DTCs. 2. Remove the rear door upper garnish molding and retainers. Refer to Rear Door Upper Garnish Molding Replacement in SI. 3. Remove the headliner push retainers. Important Do not fold or crease the headliner panel. 4. Slightly pull down on the center of the headliner panel. 5. Locate connector C405/X405, which is a light gray 22-way connector located under the center of the rear headliner panel. Tip Use a shop towel when disconnecting the rear washer hose to help absorb any washer fluid that may leak. 6. Disconnect the C405/X405 connector and the rear wiper washer hose. 7. Remove the wiring harness pass through retainer, wiring harness, C405/X405 connector and the washer hose from the roof panel. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 2037 8. Visually inspect the liftgate wiring harness as shown above and repair any damaged wires. Refer to Wiring Repairs in SI. Important After repairing the wires, wrap the wiring harness with electrical tape and install conduit. 9. Install a piece of Kent-P92565, wire harness wrap 18 mm (3/4 in) inside diameter (I.D.) by 145 mm (53/4 in) length or equivalent flexible conduit to the liftgate wiring harness. 10. Install two pieces of Kent-KT13080, Posi-Seal Plus(TM) or equivalent of electrical moisture sealant pad to the lower inner flange (1) inside the roof panel. 11. Install the liftgate connector C405/X405, wiring harness and the rear washer wiper hose back through the roof panel. 12. Connect the C405/X405 connector, the rear wiper washer hose and seat the wiring harness pass through retainer. 13. Clear any DTCs. 14. Open and close the power rear liftgate ten complete cycles. 15. Install the headliner push retainers. 16. Install the rear door upper garnish molding. 17. Verify that the condition has been fixed. Parts Information Order Kent*-KT13080, Posi-Seal Plus(TM) and P92565, Wire Harness Wrap from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 2038 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 2044 8. Visually inspect the liftgate wiring harness as shown above and repair any damaged wires. Refer to Wiring Repairs in SI. Important After repairing the wires, wrap the wiring harness with electrical tape and install conduit. 9. Install a piece of Kent-P92565, wire harness wrap 18 mm (3/4 in) inside diameter (I.D.) by 145 mm (53/4 in) length or equivalent flexible conduit to the liftgate wiring harness. 10. Install two pieces of Kent-KT13080, Posi-Seal Plus(TM) or equivalent of electrical moisture sealant pad to the lower inner flange (1) inside the roof panel. 11. Install the liftgate connector C405/X405, wiring harness and the rear washer wiper hose back through the roof panel. 12. Connect the C405/X405 connector, the rear wiper washer hose and seat the wiring harness pass through retainer. 13. Clear any DTCs. 14. Open and close the power rear liftgate ten complete cycles. 15. Install the headliner push retainers. 16. Install the rear door upper garnish molding. 17. Verify that the condition has been fixed. Parts Information Order Kent*-KT13080, Posi-Seal Plus(TM) and P92565, Wire Harness Wrap from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 07-08-47-005B > Apr > 09 > Body - Power Liftgate Opens Part Way Then Reverses > Page 2045 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Front Of The I/P (Except RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 2052 Front Of The I/P (With RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 2053 Headlamp And Panel Dimmer Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 2054 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Steering Wheel Components Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 2058 Horn Switch: Service and Repair HORN SWITCH REPLACEMENT Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Front Of The I/P (Except RPO Code Z75) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 2062 Turn Signal Switch: Diagrams Antilock Brake System Connector End Views I/P Multifunction Switch Assembly (X88/Z88) Transfer Case Shift Control Switch I/P Multifunction Switch Assembly (X88/Z88) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 2065 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required ^ J 23653-SIR Steering Column Lock Plate Compressor ^ J 42137 Cam Orientation Plate Adapter Removal Procedure Caution: Refer to SIR Caution. 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling. Important: Let the SIR coil hang freely after removal. 2. Remove the SIR coil. 3. Remove and discard the bearing retainer using J 23653-SIR and J 42137. 4. Remove the following parts from the steering column shaft assembly: 1. Turn signal switch cancel cam plate (2) 2. Turn signal switch cancel cam (3) Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 2066 1. Install the following parts onto the steering column shaft assembly: 1. Lubricate the turn signal cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam plate (2) 2. Install the new bearing retainer onto the steering shaft assembly. 3. Compress the cam orientation plate using J 23653-SIR and J 42137. 4. Firmly seat the bearing retainer into the groove on the steering shaft assembly. 5. Remove J 23653-SIR. 6. Install the SIR coil. 7. Enable the SIR system. Refer to SIR Disabling and Enabling. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Assemblies Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2072 Accelerator Pedal Position (APP) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2073 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2074 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. NOTE: Refer to Fastener Notice. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2075 - The ignition is ON. - The engine is OFF. 7. Install the knee bolster. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations RR of The Engine Compartment Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2173 Air Flow Meter/Sensor: Service and Repair MASS AIRFLOW SENSOR/INTAKE AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 2. Loosen the MAF/IAT sensor adapter clamp. 3. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2174 IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. 2. NOTE: Refer to Fastener Notice. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 2178 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. 6. IMPORTANT: Note the orientation of the battery current sensor prior to removal. Slide the battery current sensor (2) off of the negative battery cable. INSTALLATION PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 2179 1. Squeeze the negative battery cable branches together. 2. IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Front Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2276 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2277 Camshaft Position Sensor: Description and Operation CAMSHAFT ACTUATOR SYSTEM DESCRIPTION CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The camshaft (CMP) actuator system is an electro-hydraulic operated device used for a variety of engine performance and operational enhancements. These enhancements include lower emission output through exhaust gas dilution of the intake charge in the combustion chamber, a broader engine torque range, and improved fuel economy. The CMP actuator system accomplishes this by, changing the angle or timing of the camshaft, relative to the crankshaft position. The CMP actuator simply allows earlier or later intake and exhaust valve opening, during the four stroke engine cycle. The CMP actuator cannot vary the duration of valve opening, or the valve lift. During engine OFF, engine idling conditions, and engine shutdown, the camshaft actuator is held in the park position. Internal to the CMP actuator assembly is a return spring and a locking pin. During non-phasing modes of the camshaft, the return spring rotates the camshaft back to the park position, and the locking pin retains the CMP actuator sprocket to the camshaft. For the Gen IV small block engines, the park position for the CMP actuator and camshaft is, 8.5 degrees before top dead center (BTDC), which is equal to 17 crankshaft degrees BTDC, to the next cylinder in firing order. The engine control module (ECM) can only command the CMP actuator to retard the valve timing from the park position, or advance the valve timing back to the park position. The total range of valve timing authority is 31 degrees of camshaft rotation, which is equal to 62 degrees of crankshaft rotation. The control range is from the park position of 8.5 degrees camshaft, or 17 degrees of crankshaft BTDC, to 22.5 degrees camshaft, or 45 degrees crankshaft, after top dead center (ATDC). CMP ACTUATOR SYSTEM OPERATION The camshaft position (CMP) actuator system is controlled by the engine control module (ECM). The ECM sends a pulse width modulated, 12-volt signal to the CMP actuator solenoid to control the amount of pressurized engine oil, into the CMP actuator. A low reference circuit, or ground wire between the CMP actuator solenoid and the ECM completes the electrical circuit. The frequency of the pulse width modulated signal is fixed at 150 Hz. To regulate the pressurized engine oil into the CMP actuator, the solenoid uses electromagnetic force on the solenoid pintle to pulse the oil control spool valve. The pressurized engine oil is sent to unseat the locking pin, and to the vane and rotor assembly of the CMP actuator, to either retard or advance the valve timing. The ECM will control the amount of ON time applied to the solenoid, through the 12-volt signal from the ECM. The ECM uses the following inputs before assuming control of the CMP actuator, and to calculate the optimum valve timing. Engine speed - Manifold absolute pressure (MAP) - Throttle position angle - Camshaft position sensor (CMP) - Crankshaft position sensor (CKP) - Crankshaft/camshaft correlation - Engine coolant temperature (ECT) - Closed loop fuel control - Engine oil pressure (EOP) - Engine oil level - CMP actuator solenoid circuit state CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control circuit, DTC P0010 will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTIC The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position, and the actual position of the camshaft, through the 4X signal of the CMP sensor. If the difference between the actual and desired position is greater than a calibrated angle, for more than a calibrated amount of time, DTC P0011 will set. For the system descriptions covering the hydraulic/mechanical part of the CMP actuator refer to Camshaft Position (CMP) Actuator and Solenoid Valve DESCRIPTION. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2278 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION SENSOR REPLACEMENT (WITH RPO CODES LY2/LC9/LY5/LMG) REMOVAL PROCEDURE IMPORTANT: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the CMP sensor wire harness bolts (705, and 738). 4. Remove the CMP sensor wire harness (737). 5. Remove the CMP sensor (703) and O-ring seal (704). INSTALLATION PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2279 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. 5. Install the CMP sensor wire harness (737). 6. NOTE: Refer to Fastener notice. Install the CMP sensor wire harness bolts (705, and 738). Tighten the bolts to 12 N.m (106 lb in). 7. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 8. Lower the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2288 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2289 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2290 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2291 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2297 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2298 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2299 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2300 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2306 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2307 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2308 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2309 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-08-50-017B > Feb > 10 > Electrical - No Crank/No Start/Discharged or Low Battery Seat Heater Control Module: All Technical Service Bulletins Electrical - No Crank/No Start/Discharged or Low Battery TECHNICAL Bulletin No.: 09-08-50-017B Date: February 11, 2010 Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Rear Heated Seat Module) Models: 2006-2010 Cadillac DTS Built Prior to February 2, 2010 2007-2010 Cadillac Escalade, Escalade ESV 2007-2010 Chevrolet Suburban, Tahoe 2007-2010 GMC Yukon, Yukon XL Built Prior to November 30, 2009 All Equipped with Rear Heated Seat RPO KA6 Supercede: This bulletin is being revised to add build breakpoint dates. Please discard Corporate Bulletin Number 09-08-50-017A (Section 08 - Body and Accessories). Condition Some customers may comment about a no crank/no start condition or a discharged or low battery. Note This condition may be intermittent, therefore it is important to check if a revised calibration has been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the dealer. Cause This condition may be caused by the rear heated seat module (RHSM) discharging the battery by keeping the serial data bus active, which creates a cumulative continuous draw of four amps on the battery after the vehicle is shut down, until the state of charge reaches three volts. Correction Important DO NOT replace the RHSM or the battery for this concern. Reprogram the RHSM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the RHSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-08-50-017B > Feb > 10 > Electrical - No Crank/No Start/Discharged or Low Battery > Page 2314 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2320 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2321 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2322 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 2323 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-08-50-017B > Feb > 10 > Electrical - No Crank/No Start/Discharged or Low Battery > Page 2328 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2329 Temperature Versus Resistance Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2330 Front Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2331 Engine Coolant Temperature (ECT) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2332 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System (Vac-N-Fill). See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2333 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. 2. NOTE: Refer to Fastener Notice. Install the ECT sensor. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Draining and Filling Cooling System (Vac-N-Fill). See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2356 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2375 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2407 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2408 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2409 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2410 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2412 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2413 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2414 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2415 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2416 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2417 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2418 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2419 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2420 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2421 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2422 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2423 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2424 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2425 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2426 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2427 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 Crankshaft Position (CKP) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement CRANKSHAFT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the Crankshaft Position System Variation Learn whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2432 1. Install the CKP sensor. 2. NOTE: Refer to Fastener Notice. Install the CKP sensor bolt. Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2433 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn CRANKSHAFT POSITION SYSTEM VARIATION LEARN 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. 6. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: A CKP sensor replacement - An engine replacement - A ECM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications Fuel Level Sensor: Specifications FUEL LEVEL SPECIFICATIONS The information in this table is intended for use with the J 33431-C Signal Generator and Instrument Panel Tester. The fuel level sensor values represent the test values to be used on the Signal Generator to drive the fuel gage display to the indicated positions. Vehicles that require more than one fuel level sensor calculate gage position from many possible resistance combinations of fuel levels between the two tanks. Therefore, the values in the table may not correlate directly to readings taken from the vehicle primary or secondary sending units. The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (1500 Series) FUEL LEVEL SENSOR REPLACEMENT (1500 SERIES) REMOVAL PROCEDURE 1. Remove the fuel tank module. 2. Using a small pick like tool, push in the retainer (1) in order to disengage the electrical connector. 3. Remove the fuel level sensor electrical connector from the module cover. 4. Push the level sensor locking tangs (2) in towards the inside of the module bucket. 5. Slide the fuel level sensor up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2439 6. Remove the fuel level sensor from the module. INSTALLATION PROCEDURE 1. Install the fuel level sensor to the module. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2440 2. Position and slide the fuel level sensor down. 3. Ensure that the level sensor tangs (2) are engaged at the bucket. 4. Install the fuel level sensor electrical connector to the module cover. 5. Ensure that the retainer (1) engaged the module cover. 6. Install the fuel tank module. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2441 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (1500 Series With RPO Code E85) FUEL LEVEL SENSOR REPLACEMENT (1500 SERIES WITH RPO CODE E85) REMOVAL PROCEDURE 1. Remove the fuel tank module. 2. Disengage the retainers (1) and slide the fuel level sensor up. 3. Remove the fuel level sensor from the module. 4. Disconnect the fuel level sensor electrical connectors (1). INSTALLATION PROCEDURE 1. Connect the fuel level sensor electrical connectors (1). 2. Install the fuel level sensor to the module. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2442 3. Position and slide the fuel level sensor down until the retainers (1) engage the sensor. 4. Install the fuel tank module. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2443 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (2500 - 43.5L (11.5 Gal) Tank - Rear) FUEL LEVEL SENSOR REPLACEMENT (2500 - 43.5L (11.5 gal) TANK - REAR) REMOVAL PROCEDURE 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor electrical connector (3) from under the module cover. 3. Release the level sensor retaining clip (1). 4. Slide the fuel level sensor (2) down off the bucket. INSTALLATION PROCEDURE 1. Slide the fuel level sensor (2) up onto the bucket until the sensor engages the retaining tab (1). 2. Connect the fuel level sensor electrical connector (3) under the module cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2444 3. Install the fuel tank module. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2445 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (2500 - 98.4L (26 Gal) Tank - Front) LEVEL SENSOR REPLACEMENT (2500 - 98.4L (26 GAL) TANK - FRONT) REMOVAL PROCEDURE 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor electrical connector (1) from under the module cover. 3. Release the fuel level sensor retaining clip (1). 4. Slide the fuel level sensor down off of the bucket. INSTALLATION PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (1500 Series) > Page 2446 1. Slide the fuel level sensor up onto the bucket until the sensor engages the retaining tab (1).. 2. Connect the fuel level sensor electrical connector (1) under the module cover. 3. Install the fuel tank module. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Chassis Fuel Components (Short Wheel Base) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2450 Fuel Tank Pressure (FTP) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (1500 LWB - 117.3L (31 Gal) Tank + E85) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (1500 LWB - 117.3L (31 Gal) Tank + E85) FUEL TANK PRESSURE SENSOR REPLACEMENT (1500 LWB - 117.3L (31 gal) TANK + E85) REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (1500 LWB - 117.3L (31 Gal) Tank + E85) > Page 2453 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (1500 SWB - 98.4L (26 Gal) Tank + E85) FUEL TANK PRESSURE SENSOR REPLACEMENT (1500 SWB - 98.4L (26 gal) TANK + E85) REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the evaporative emission (EVAP) line quick connect fitting from the vent valve and reposition the line out of the way. 3. Using a slight rocking motion while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Position the EVAP line and connect the EVAP line quick connect fitting to the vent valve. 3. Install the fuel tank. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (1500 LWB - 117.3L (31 Gal) Tank + E85) > Page 2454 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (1500 Series) FUEL TANK PRESSURE SENSOR REPLACEMENT (1500 Series) REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (1500 LWB - 117.3L (31 Gal) Tank + E85) > Page 2455 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (2500 Series) FUEL TANK PRESSURE SENSOR REPLACEMENT (2500 Series) REMOVAL PROCEDURE IMPORTANT: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Remove the intermediate fuel and evaporative emission (EVAP) lines. 2. Gently pry straight up, in order to remove the fuel pressure sensor. INSTALLATION PROCEDURE 1. Lubricate the seal on the fuel pressure sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (1500 LWB - 117.3L (31 Gal) Tank + E85) > Page 2456 2. Press the fuel pressure sensor into the line. 3. Install the intermediate fuel and EVAP lines. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations RR of The Engine Compartment Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2460 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2461 Intake Air Temperature Sensor: Service and Repair MASS AIRFLOW SENSOR/INTAKE AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 2. Loosen the MAF/IAT sensor adapter clamp. 3. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2462 IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. 2. NOTE: Refer to Fastener Notice. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Right Side Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2466 Front Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2469 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2470 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2471 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2472 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 Knock Sensor: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2484 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2523 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2524 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2525 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2526 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2527 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2528 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2529 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2530 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2532 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2534 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2535 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2536 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2537 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2538 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2539 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2540 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 Knock Sensor: Connector Views Knock Sensor (KS) - 1 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Knock Sensor (KS) - 2 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2562 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement KNOCK SENSOR 1 REPLACEMENT REMOVAL PROCEDURE 1. Remove the left front wheel and tire. 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). INSTALLATION PROCEDURE 1. NOTE: Refer to Fastener Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2565 Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Install the left front wheel and tire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2566 Knock Sensor: Service and Repair Knock Sensor 2 Replacement KNOCK SENSOR 2 REPLACEMENT REMOVAL PROCEDURE 1. Remove the right front wheel and tire. 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). INSTALLATION PROCEDURE 1. NOTE: Refer to Fastener Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2567 Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (2) to knock sensor. 3. Install the right front wheel and tire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Top Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2571 Right Side Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2572 Front Of The Engine Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2573 Manifold Absolute Pressure (MAP) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2574 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold sight shield. 2. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2575 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor. 4. Install the intake manifold sight shield. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Diagrams Oil Level Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks Oil Pressure Sensor: Customer Interest Engine - Low Oil Lamp ON/Oil Leaks TECHNICAL Bulletin No.: 07-06-01-004A Date: November 25, 2008 Subject: All Vortec(R) GEN IV V8 Engines - LY2 LS4 LC9 LH6 LMG LY5 LS2 L76 LY6 L92 LS7, Low Oil Level Indicator Lamp On and/or Engine Oil Leak (Reseal Oil Pressure Sensor) Models Supercede: This bulletin is being updated to include a labor operation number for CTS-V and Corvette models. Please discard Please discard Corporate Bulletin Number 07-06-01-004 (Section 06 Engine/Propulsion System). Condition Some customers may comment on a low oil level indicator lamp on and/or engine oil leak. Upon further investigation, the technician may find that the oil leak is at the oil pressure sensor that is threaded into the valve lifter oil manifold (VLOM) assembly and/or engine valley cover. Correction If the engine oil leak was found to be at the engine oil pressure sensor, then remove the oil pressure sensor and reseal with a pipe sealant with Teflon or equivalent, P/N 12346004 (in Canada, P/N 10953480). Refer to Engine Oil Pressure Sensor and/or Switch Replacement in SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks > Page 2587 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks Oil Pressure Sensor: All Technical Service Bulletins Engine - Low Oil Lamp ON/Oil Leaks TECHNICAL Bulletin No.: 07-06-01-004A Date: November 25, 2008 Subject: All Vortec(R) GEN IV V8 Engines - LY2 LS4 LC9 LH6 LMG LY5 LS2 L76 LY6 L92 LS7, Low Oil Level Indicator Lamp On and/or Engine Oil Leak (Reseal Oil Pressure Sensor) Models Supercede: This bulletin is being updated to include a labor operation number for CTS-V and Corvette models. Please discard Please discard Corporate Bulletin Number 07-06-01-004 (Section 06 Engine/Propulsion System). Condition Some customers may comment on a low oil level indicator lamp on and/or engine oil leak. Upon further investigation, the technician may find that the oil leak is at the oil pressure sensor that is threaded into the valve lifter oil manifold (VLOM) assembly and/or engine valley cover. Correction If the engine oil leak was found to be at the engine oil pressure sensor, then remove the oil pressure sensor and reseal with a pipe sealant with Teflon or equivalent, P/N 12346004 (in Canada, P/N 10953480). Refer to Engine Oil Pressure Sensor and/or Switch Replacement in SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-06-01-004A > Nov > 08 > Engine - Low Oil Lamp ON/Oil Leaks > Page 2593 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sensor: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sensor: > 07-09-41-004 > Jun > 07 > Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sensor: > 07-09-41-002 > Jan > 07 > SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sensor: > 07-09-41-002 > Jan > 07 > SRS - Air Bag Lamp ON/DTC B0081 Set > Page 2607 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sensor: > 07-09-41-002 > Jan > 07 > SRS - Air Bag Lamp ON/DTC B0081 Set > Page 2621 Disclaimer Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2622 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2623 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Sealers, Adhesives, and Lubricants. Notice: Refer to Fastener Notice. 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 N.m (26 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2624 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 N.m (26 lb ft). 5. Install the intake manifold. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 Oxygen Sensor: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125 11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125 11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) TYCO/AMP CONNECTORS (43-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the release tool being used for the larger terminals. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 View of the release tool being used for the larger terminals. View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) YAZAKI CONNECTORS (2-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) YAZAKI CONNECTORS (16-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, pull the two connector halves apart. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. IMPORTANT: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 View of the female half of the connector with male terminals. View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 GMLAN WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: DuraSeal splice sleeves - A wire stripping tool - J 38125-8 Crimping Tool (GM P/N 12085115) - J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 splice. 1. Open the harness by removing any tape: IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except coaxial. - Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs HEATED OXYGEN SENSOR WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: DuraSeal splice sleeves to crimp and seal connections Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: DuraSeal splice sleeves, in order to repair the SIR/SRS wiring - A special crimping tool - A heat torch - An instruction manual The DuraSeal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR REPAIR (PLASTIC BODY AND TERMINAL METAL PIN) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: Various terminated leads for sensing and diagnostic module (SDM) terminal replacement - Various connector positive assurance (CPA) locks for SIR/SRS connectors - Base of steering column pigtail connectors part number 12085514 - Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS COMPONENT WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. 1. Open the harness by removing any tape: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. - Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. - Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 - Using the heat torch, apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 4. Re-assemble the cable. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (Except LY6 And L92) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (Except LY6 And L92) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LC9, LMG, LY5, LY2, L76) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (Except LY6) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice Heated Oxygen and Oxygen Sensor Notice Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 2726 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice Silicon Contamination of Heated Oxygen Sensors Notice Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 2727 Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice Excessive Force and Oxygen Sensor Notice Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 2728 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice Heated Oxygen Sensor Resistance Learn Reset Notice Notice: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 1 SENSOR 1 (1500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Remove the connector position assurance (CPA) retainer. 5. Disconnect the engine wiring harness electrical connector (2) from the HO2S. 6. Remove the HO2S electrical connector clip (1) from the fuel line clip. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2731 7. Remove the CPA retainer (2). 8. Remove the engine wiring harness electrical connector clip (1) from the fuel line clip. 9. Disconnect the engine wiring harness electrical connector (3) from the HO2S. 10. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Remove the HO2S (1 or 2). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2732 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE Refer to Component Fastener Tightening Notice. 2. Install the HO2S (1 or 2). Tighten the sensor to 42 N.m (31 lb ft). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Install the HO2S electrical connector clip (1) to the fuel line clip. 5. Connect the engine wiring harness electrical connector (2) to the HO2S. 6. Install the CPA retainer. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2733 7. Connect the engine wiring harness electrical connector (3) to the HO2S. 8. Install the engine wiring harness electrical connector clip (1) to the fuel line clip. 9. Install the CPA retainer (2). 10. Install the front propeller shaft to the front differential, if equipped with 4WD. 11. Lower the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2734 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 1 SENSOR 2 (1500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (1). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). 4. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2735 Remove the HO2S (5). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (5). Tighten the sensor to 42 N.m (31 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2736 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). 4. Install the CPA retainer (1). 5. Lower the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2737 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 2 SENSOR 1 (1500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (1). 4. Remove the HO2S clip (8) from the engine wiring harness. 5. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2738 Remove the HO2S (3). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (3). Tighten the sensor to 42 N.m (31 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2739 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (1). 4. Install the CPA retainer (2). 5. Install the HO2S clip (8) to the engine wiring harness. 6. Lower the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2740 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 2 SENSOR 2 (1500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (4). 3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector clip from the engine harness clip (6). 5. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2741 Remove the HO2S (4). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (4). Tighten the sensor to 42 N.m (31 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2742 3. Install the HO2S electrical connector clip to the engine harness clip (6). 4. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 5. Install the CPA retainer (5). 6. Lower the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2743 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 1 SENSOR 1 (1500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Remove the connector position assurance (CPA) retainer. 5. Disconnect the engine wiring harness electrical connector (2) from the HO2S. 6. Remove the HO2S electrical connector clip (1) from the fuel line clip. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2744 7. Remove the CPA retainer (2). 8. Remove the engine wiring harness electrical connector clip (1) from the fuel line clip. 9. Disconnect the engine wiring harness electrical connector (3) from the HO2S. 10. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Remove the HO2S (1 or 2). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2745 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE Refer to Component Fastener Tightening Notice. 2. Install the HO2S (1 or 2). Tighten the sensor to 42 N.m (31 lb ft). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Install the HO2S electrical connector clip (1) to the fuel line clip. 5. Connect the engine wiring harness electrical connector (2) to the HO2S. 6. Install the CPA retainer. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2746 7. Connect the engine wiring harness electrical connector (3) to the HO2S. 8. Install the engine wiring harness electrical connector clip (1) to the fuel line clip. 9. Install the CPA retainer (2). 10. Install the front propeller shaft to the front differential, if equipped with 4WD. 11. Lower the vehicle. Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 1 SENSOR 2 (1500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2747 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (1). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). 4. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Remove the HO2S (5). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2748 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (5). Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). 4. Install the CPA retainer (1). 5. Lower the vehicle. Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 2 SENSOR 1 (1500 SERIES) REMOVAL PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2749 NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (1). 4. Remove the HO2S clip (8) from the engine wiring harness. 5. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2750 Remove the HO2S (3). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (3). Tighten the sensor to 42 N.m (31 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2751 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (1). 4. Install the CPA retainer (2). 5. Install the HO2S clip (8) to the engine wiring harness. 6. Lower the vehicle. Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) HEATED OXYGEN SENSOR REPLACEMENT- BANK 2 SENSOR 2 (1500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2752 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (4). 3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector clip from the engine harness clip (6). 5. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Remove the HO2S (4). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2753 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (4). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S electrical connector clip to the engine harness clip (6). 4. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 5. Install the CPA retainer (5). 6. Lower the vehicle. Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (2500 Series) HEATED OXYGEN SENSOR REPLACEMENT - BANK 1 SENSOR 1 (2500 SERIES) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2754 REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement. 3. Remove the connector position assurance (CPA) retainer (2). 4. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). 5. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2755 Remove the HO2S (1). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (1). Tighten the sensor to 42 N.m (31 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2756 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). 4. Install the CPA retainer (2). 5. Install the front propeller shaft to the front differential, if equipped with 4WD. 6. Lower the vehicle. Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (2500 Series) HEATED OXYGEN SENSOR REPLACEMENT - BANK 1 SENSOR 2 (2500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2757 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (1). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). 4. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Remove the HO2S (4). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2758 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (4). Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). 4. Install the CPA retainer (1). 5. Lower the vehicle. Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) HEATED OXYGEN SENSOR REPLACEMENT - BANK 2 SENSOR 1 (2500 SERIES) REMOVAL PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2759 NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (1). 4. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2760 Remove the HO2S (2). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (2). Tighten the sensor to 42 N.m (31 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2761 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (1). 4. Install the CPA retainer (5). 5. Lower the vehicle. Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series) HEATED OXYGEN SENSOR REPLACEMENT - BANK 2 SENSOR 2 (2500 SERIES) REMOVAL PROCEDURE NOTE: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. - Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. - Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2762 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical connector. 4. Remove the HO2S electrical connector clip from the engine harness clip (4). 5. NOTE: Refer to Excessive Force and Oxygen Sensor Notice. Remove the HO2S (3). INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) > Page 2763 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice. 2. Install the HO2S (3). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S electrical connector clip to the engine harness clip (4). 4. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector. 5. Install the CPA retainer (3). 6. Lower the vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Park Neutral Position (PNP) Switch Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2767 Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70 2 - Park/Neutral Position (PNP) Switch C175 C175 1 - Automatic Transmission 2 - C175 Vehicle Speed Sensor (VSS) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2768 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Transmission Control Module (TCM) Transmission Control Module (TCM) 1 - Engine Harness 2 - Transmission Control Module (TCM) 3 - Transmission Control Module (TCM) Connector Harness Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2771 Transmission Position Switch/Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Park/Neutral Position (PNP) Switch Connector, Wiring Harness Side Park/Neutral Position (PNP) Switch Connector, Wiring Harness Side Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2774 Transmission Position Switch/Sensor: Adjustments 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine OFF. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2777 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2778 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2779 Transmission Position Switch/Sensor: Service and Repair 4L80-E/4L85-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park/Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into Neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Disconnect the park/neutral position (PNP) switch electrical connector (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2780 6. Disconnect the selector cable from the range selector lever ball stud. 7. Remove the control lever to the manual shaft nut (1). 8. Remove the control lever (2) from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2781 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park/neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Position the J 41364-A onto the PNP switch. Ensure that the 2 slots on the switch where the manual shaft is inserted are lined up with the lower 2 tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2782 8. Install the control lever (2) to the manual shaft. 9. Install the control lever to the manual shaft nut (1). Tighten the nut to 25 N.m (18 lb ft). 10. Connect the range selector cable to the range selector lever ball stud. 11. Connect the PNP switch electrical connector (1). 12. If equipped with 4WD, install the front propeller shaft. 13. Lower the vehicle. 14. Check the PNP switch for proper operation. The engine must start in the Park (P) or Neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 2787 Vehicle Speed Sensor: Diagrams 4L80-E/4L85-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor (VSS) Vehicle Speed Sensor (VSS) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2788 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Notice: Refer to Fastener Notice. 4. Install the VSS bolt (2). Tighten the bolt to 11 N.m (97 lb in). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2789 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Assemblies Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2794 Accelerator Pedal Position (APP) Sensor Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2795 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2796 INSTALLATION PROCEDURE 1. Position the accelerator pedal to the accelerator pedal bracket. 2. NOTE: Refer to Fastener Notice. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2797 - The ignition is ON. - The engine is OFF. 7. Install the knee bolster. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations RR of The Engine Compartment Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2803 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2806 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2808 Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2809 Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2810 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Basic Knowledge Required GENERAL ELECTRICAL DIAGNOSIS BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2812 US English/Metric Conversion (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2813 US English/Metric Conversion (Part 2) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2814 Decimal And Metric Equivalents (Part 1) Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2815 Decimal And Metric Equivalents (Part 2) Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: - CAUTION: Refer to SIR Caution. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. - NOTE: Refer to OBD II Symbol Description Notice. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2816 This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2817 IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS TOOLS REQUIRED J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. SALT WATER SPRAY Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. HIGH TEMPERATURE CONDITIONS If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. LOW TEMPERATURE CONDITIONS Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2818 DUPLICATING FAILURE CONDITIONS - If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2819 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. IMPORTANT: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2820 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. - Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2821 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2822 circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. TESTING FOR PROPER TERMINAL CONTACT IN BUSSED ELECTRICAL CENTERS (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2823 Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. FLAT WIRE (DOCK AND LOCK) CONNECTORS There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2824 - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning IMPORTANT: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. Testing for Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice. IMPORTANT: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2825 or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 Test Light - Probe Kit NOTE: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2826 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2828 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Release the rear lower half of the wiredress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2829 Release the tabs that are holding the wiredress cover to the connector body. 6. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2830 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2831 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) BOSCH CONNECTORS (ECM) TOOLS REQUIRED J-38125Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2832 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2833 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2834 IMPORTANT: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2835 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2836 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2837 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2838 the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2839 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2840 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2841 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2842 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2843 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2844 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) DELPHI CONNECTORS (12-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Release the lower wiredress cover locking tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 Release the upper wiredress cover locking tab. 4. Once the locks are unlocked, lift the dress cover off. 5. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 6. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. While depressing the lock, remove the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 IMPORTANT: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors KOSTAL CONNECTORS Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. 7. Use a small flat-blade tool to move the front TPA to the release position. IMPORTANT: The front TPA cannot be removed from the connector. Only move it to the release point. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors MOLEX CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 3. Disconnect the connector from the component. 4. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 5. Cut the tie wrap that holds the wires to the connector body. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 6. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 7. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 8. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 9. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors SUMITOMO CONNECTORS TOOLS REQUIRED J-38125 Terminal Repair Kit Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 TERMINAL REMOVAL PROCEDURE 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. - Terminal (1) - Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) TYCO/AMP CONNECTORS (DOOR MODULE) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Tahoe 4wd Workshop Manual (V8-5.3L (2007)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component.